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GASIFIER SYSTEM
ADISSERTATION
Submitted in partial fulfillment of the
requirements for the award of the degree
of
MASTER OF TECHNOLOGY
in
ALTERNATE HYDRO ENERGY SYSTEMS
By
PRAFUL IINKAR SUTKAR
-RAL- Cl,
(ca' X20208 .eo®e'e d
ACCiNO•.11 ee .e. ~h
3rGfll-o._
DO[g•.,.ee.e.eee.e.ees ~ F
I hereby certify that the work which is being presented in this dissertation work, entitled,
"PERFORMANCE ANALYSIS OF BIOMASS GASIFIER SYSTEM", in partial fulfillment of the
requirements for the award of the degree of Master Of Technology in "Alternate Hydro Energy
Systems", submitted in Alternate Hydro Energy Center, Indian Institute of Technology, Roorkee is
an authentic record of my own work carried out during the period from July 2009 to June 2010
under the supervision of Dr.M.P.Sharma, and Dr.R.P.Saini , Associate Professor, Alternate
Hydro Energy Center,Roorkee.
I have not submitted .the matter embodied in this dissertation for award of any other degree.
CERTIFICATE
This is to certify that the above statement made by the candidate is correct to the best of my
knowledge.
Dr.M.P.Sharma r.R.P.Saini
Associate Professor, Associate Professor,
Alternate Hydro Energy Center, Alternate Hydro Energy Center,
Indian Institute of Technology, Indian Institute of Technology,
Roorkee, 247667 Roorkee, 247667
ACKNOWLEDGEMENT
ii
ABSTRACT
In India, in spite of the highest priority given to rural electrification, about 80,000 villages
remain yet to be electrified. Most of these villages are located in remote areas, with very low
load densities. In remote areas where transmission of grid power is totally uneconomical, off
grid electrification can be undertaken through renewable energy systems such as Gasifier
technology.
In present study, the 5kW downdraft gasifier coupled to engine-generator is used for
electrification. Performance analysis of biomass gasifier instated at RET Park, AHEC are carried
out.
The proximate analysis of wood is carried out having the moisture contain of 12% on
wet basis having fixed carbon, volatile matter and ash contained as 16%, 82%, and 1%
respectively. The calorific value of the wood was measured as 4404 kcal kg" '.
Biomass consumption at different load, i.e.at load 1kW, 2kW, 3kW, and 4kW 1.5, 3, 3.5,
4, and 4.5 kg/hr respectively. Overall efficiency of biomass gasifier system operated on 100%
producer gas mode has been found as 12.5% at 4kW load whereas at 1kW, 2kW, 3kW load
conditions, the values of efficiencies has been observed as 9.38%, 10%, and 11.25 %
respectively.
Further an attempt has also made to analysis that energy cost for higher capacity of
systems. Energy cost for 100 % producer gas mode of operation for 5, 10, 20, 30, and 40kW of
systems has been found as Rs.23.44/,Rs.19.11/,Rs.16.15/, Rs.15.66/, and Rs.14.72/kWh
respectively. However the values for dual fuel mode are found as Rs.26.08, Rs.22.52, Rs.18.84,
Rs.18.58, and Rs.17.59/kWh respectively and for diesel mode as Rs.29.36, Rs.25.96, Rs.22.28,
Rs.21.93, and Rs.20.98/kWh respectively.
iii
TABLE OF CONTENTS
CANDIDATE'S DECLARATION i
ACKNOWLEDGEMENT ii
ABSTRACT iii
CONTENTS iv-vii
LIST OF TABLES viii
LIST OF FIGURES ix
1 INTRODUCTION 1-17
1.1 GENERAL 1
1.2 CONVENTIONAL ENERGY SOURCES 1
1.3 ELECTRICITY SCENARIO OF INDIA 2
1.4 RENEWABLE ENERGY 3
1.5 RENEWABLE ENERGY SOURCES 4
1.6 EVOLUTION OF RENEWABLE ENERGY IN INDIA 5
1.7 THE RENEWABLE ENERGY OPTIONS 6
1.8 GOVERNMENT POLICY 7
1.9 RURAL ELECTRIFICATION 8
1.10 RENEWABLE ELECTRICITY 8
1.10.1 SPV based power system 9
1.10.1.1 Types of SPV system 9
1.10.1.1.1 Grid connected 9
1.10.1.1.2 Off grid connected 9
1.10.2 Wind Energy System 9
1.10.3 Small Hydro Energy 10
1.10.4 Ocean Energy 10
1.10.5 Geothermal Energy 11
1.10.6 Biomass Energy 12
1.10.6.1 Conversion Of Biomass To 12
Electricity Technical Option
iv
1.10.6.2 Biomass gasification efforts in India 14
1.10.6.3 Application of gasifier 15
1.10.6.3.1 Generation of Producer gas 15
1.10.6.3.2 Production of mechanical or electrical 15
power
1.10.6.3 .3 Large scale applications (500 kW and 15
above)
1.10.6.3 .4 Medium scale applications (30 -500 kW 15
1.10.6.3 .5 Small-scale applications (7 - 30 kW) 15
1.10.6.3 .6 Micro scale applications (1 - 7 kW) 16
1.11 OBJECTIVES OF THE STUDY 16
1.12 ORGANIZATION OF DESERTATION WORK 16
v
3.3.3 Cross-draught gasifier 33
3.3.4 Fluidized bed gasifier 34
3.4 COMPONENT OF GASIFIER BASED ELECTRICAL 36
GENERATION SYSTEM
3.4.1 Gasifier Reactor 36
3.4.2 Cleaning System 36
3.4.3 Cooling System 37
3.4.4 Gas supply manifold 37
3.4.5 Gas Engine 37
3.4.6 Generator 39
4.6 Gas Production Rate And Air Flow Rate In The System 48
4.10 FINANCIAL ANALYSIS 51
vi
4.10.1 Capacity utilization factor of biomass Gasifier Power 52
project
4.10.2 Capital cost of biomass gasifier power project 52
4.10.3 Levelized unit cost of electricity 52
6 CONCLUSION 66
REFERENSES 67
vii
LIST OF TABLES
5.3 57
Physical properties and proximate Composition of eucalyptus
wood
viii
LIST OF FIGURES
ix
CHAPTER 1
INTRODUCTION
1.1 GENERAL
Energy is a crucial input in the process of economic, social and industrial development
and is the key to industrial development for the promotion of economic and social wellbeing
of the world population. The growth of world population, coupled with the improved
standard of living, has escalated the growth of energy usage since the turn of this century.
The consumption of world's fossil fuel is a pulse action of a relatively short duration in long
history of human existence. It took millions of years for the earth to fertilize and to store
fossil fuels in convenient forms, but the present human population may take only 300 to 400
years to use them up completely. The rapid increase in energy usage during the past 50 to
100 years cannot continue indefinitely as the earths finite supply are likely to exhaust.
The fossil fuels have powered the tremendous industrial and economic development of
the developed countries. The oil crisis of 1973 served the warning that fossil fuels were
neither inexhaustible nor any cheaper. This holds true for oil and natural gas too. The
developing countries, like India, were the ones who were the most severely hit by this crisis
and added to their problems for rapid - industrial development.
Energy has become an integral part of development of a society, as it is required for
agriculture, drinking water supply, lighting, healthcare, tele-communication, and industrial
activities and for all aspects of everyday life. Provision of lighting and cooking energy for
rural and remote areas is still a major issue in many developing countries including India.
The overall electricity consumption in India is quite low, as evident from the national
average per capita electricity consumption of about 350 kWh per annum. There is also
disparity in the electricity consumption in the urban and rural areas. Owing to about 80% of
the population live in rural areas and consume only 30% electricity in Indian context.
1
respectively, Productions are 5,624,827 thousand short tons/year, 75,226 million barrels/day
and 2,569 trillion cubic meter respectively and consumptions are 5,174.47 million short
tons/year, 28,460 million barrels/day and 82.2 trillion cubic feet respectively. The India's
conventional energy sources i. e. Coal, Oil and Natural gas reserves are 2,76,110 million
tons, 732.20 million tons and 793.0 billion cubic feet respectively, Productions are 352.60
million tons/year, 32,032 thousand tons/day and 29,714 million cubic meter respectively and
consumptions are 330.90 million tons/year, 22916 thousand tons/day and 28,037 million
cubic meters respectively.
Comparison to World, India's reserves, production and consumption of Coal, Oil and
Natural gases i. e. reserves are 28.14%, 0.54% and 0.02% respectively, productions are
14.74%, 0.32% and 0.001 % respectively and consumptions are 7.1%, 0.61% and 0.03%
respectively. These reserves of fossil fuels can be considered part of the balance sheet of the
global energy financial statement. The Conventional energy sources contribute nearly 80%
of the world's total energy consumption. The renewable energy sources, such as Nuclear,
Hydroelectric, Geothermal and Solar, all together to make up between 15-20% of world's
energy consumption. There are so many drawbacks of conventional energy sources like rapid
depletion, which will create a severe unbalance situation in the world energy scenario. It is
an exhaustible source of energy. Also severe environmental pollution and initial generation I
period and cost is more. It can be endangered by foreign power since it is not informally
available in the world.
N
electricity (peak demand) is about 14%. The transmission and distribution losses are
estimated between 26 and 32%.
In January 2003, India had an installed generating capacity of nearly 107 GW. This
includes thermal (coal, gas, and liquid fuel), hydro, nuclear, and wind power. Out of the total
installed capacity, 90% is owned by the public sector (60% under state government and 30%
under the central government) and the balance (10%) by the private sector. The annual
electricity generation in the utilities is presently about 500 BU (billion units). There is also a
constituency of captive power generation, to the tune of 14000 MW (1998/99) as per the
government estimate.
From the Fig. 1.1 it is seen that in India's power capacity for coal, large hydro is 52%
and 25% respectively, whereas renewable energy contributes 9% in comparison with natural
gas 10% and nuclear energy is 3%.
The breakup of energy resources is presented in the table- 1.1 .From table 1.1 it is
seen that total cumulative renewable energy achievement on March 2010 from grid
interactive is 16816MW and from off grid is 403MW.
L!
Table 1.1 Renewable Energy P tial a Achievement in India, March 2010[1].
Grid Interactive
Wind Power 11807
Biomass 865
Waste to energy 65
Solar Power 10
Off Grid
Biomass Power 232
Waste to energy 47
Solar PV 2
TOTAL 17219
5
dissemination, and demonstration of various Renewable Energy Technologies (RETs).
However, in comparison with the conventional sector, these programmers were low in
investments in RET promotion. Between 1980 and 1992, the cumulative government
expenditure for the renewable energy sector totaled only Rsll .55 billion, as compared to
Rs812 billion for the power sector, Rs35 billion for the petroleum sector, and Rs158.5 billion
for the coal sector. Likewise, in the Eighth Plan (1992-97), the allocations for renewable
energy were about 0.8% of the total funds allocated for the energy sector.
In the late eighties and early nineties, the realization grew that somehow private sect
had to be involved to achieve greater penetration of renewable in the energy sector. Instead
pushing renewable in a limited way through a subsidy driven programmed, it was that the]
was a need for appropriate policy framework and fiscal benefits which could create
environment a encouraging private sector to invest in renewable energy projects. It was
envisaged that the role of the Department of Non-conventional Energy Sources (DNES) had
to change from that of an implementing agency to facilitator. As a result, the Department of
Non-conventional Energy Sources (DNES) was converted into a full-fledged Ministry of
New and Renewable Energy (MNRE) in July 1992. Since 1992, the Ministry initiative has
been largely in the direction of creating an environment that facilitated greater penetration of
renewable through a market led approach.
0
i
(i.) 100% depreciation for tax purposes in the first year of the installation of the systems.
(ii) No excise duty on manufacture of most of the finished products.
(iii) Low import tariffs for capital equipment and most materials and components.
(iv) Soft loans (2.5%-10.3%) to manufacturers and users.
(v) Years tax holiday for power generation projects.
(vi) Remunerative price for the power generated through renewable energy systems, fed to
the grid.
vii) Banking and wheeling of power.
viii) Third party sale of renewable power.
To encourage power generation from renewable, the MNRE has been working
closely with State Governments and State Electricity Boards/State power corporations to
evolve conducive policies for renewable energy projects. As a result, more than 12 States
have announced their policies for setting up of renewable projects in their state.
The Ministry is in the process of formulating a comprehensive energy policy, which
will deal with various policy issues relevant to development and large scale diffusion of
renewable energy technologies, develop and implement innovative self-sustaining packages
for diffusion of solar photovoltaic systems in the State. Encouraged by the success of the
programmer, the State Government has declared the Sagar Island in the Sunderban area as a
"Solar Island" which has been electrified primarily through solar photovoltaic. Further the
Prime Minister of India has announced a goal of 10 percent share for RE or 10,000 MW in
the power generation capacity to be added during the period up to 2012.
7
power and energy services to these areas. These independent power-producing units may the
sources of non-conventional or renewable energy base power generating system.
8
together, called a photovoltaic array, in order to provide sufficient power for common
electrical uses.
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10
applications, including electricity generation. Electricity conversion systems use either the
warm surface water or boil the seawater to turn a turbine, which activates a generator.
11
Fig. 1.4 Schematic of Geothermal Power Plant
12
Steam engines were considered robust for installation and operation in rural areas.
However, this technology suffered major setback due to implementation of the regulations
regarding certified operators for the boilers and non-availability of engines.
BIGCC (Biomass Integrated Gasification Combined Cycle) with steam-injected gas
turbine was expected to have much higher conversion efficiency. But development of this
technology was not marked. Most of these projects aimed at linking producer gas to steam
turbines could not proceed beyond gasifier design. The concept of bagasse gasification also
did not show much potential for commercial implementation. The only viable technologies
for commercialization of electricity production from biomass are: Biomass gasification
coupled with an IC engine operating on producer gas and boiler-steam turbine route (or
cogeneration) .
The technology of biomass gasification is suitable for distributed and decentralized
generation in remote villages. A single biomass gasification unit can generate up to 500 kW
powers, while a gasification station (with fluidized bed design) could have capacity of about
5 MW. Typically, the Costs of biomass gasifier-based electricity generation range from Rs. 4
to 4.5 crore/MWe. Active and intense research in this area is going on all around the world in
terms of better design and optimization of process parameters, which is aimed at improving
energy efficiency of the gasifier that would bring down the cost of electricity generation in
the near future.
Bagasse-based cogeneration has already been adopted by many sugar mills. In this
route, high pressure steam is first utilized for generation of electricity and later for meeting
the heat requirements of the process. Thus, the overall efficiency of fuel utilization is quite
high, in the range of 60%. Typically, the cost of electricity produced through this route is
somewhat cheaper than biomass gasification route; in the range of Rs.3-4 crore/MWe.
Revenues earned from electricity cogeneration have improved economy of sugar mills.
However, cogeneration units are preferred only for capacities >5MW and these units could
be installed and implemented in an industrial area. Thus, they are not suitable for
applications in remote rural areas where grid connectivity is not possible. Secondly, the
steam turbine-based technology has already reached maturity. Any path-breaking efficiency
improvement is, thus, not feasible. Thus, in terms of technology development and
breakthrough for large capacity systems, gasification combined with IC engines may turn out
a better option.
13
1.10.6.2 Biomass gasification efforts in India
The biomass gasification program in India started mainly as a R&D effort with joint
efforts of MNES, various academic institutions and private entrepreneurs [6]. These efforts
were initiated in the mid-1980s for development and subsequent commercialization of an
efficient and economically viable technology for decentralized electricity generation from
biomass, especially in remote and rural areas. The MNES set up five Gasifier Action
Research Projects at I.I.T. Bombay, I.I.T. Delhi, and I.I.Sc. Bangalore, M.K. University
Madurai and SPRERI, V.V. Nagar. Research in these centers contributed immensely towards
technology development, prototype fabrication and transfer of technology to commercial
manufacturers. Combustion, Gasification and Propulsion Laboratory (CGPL) at I.I.Sc.
Bangalore developed downdraft, atmospheric gasification technology for up to 500 kW
systems along with effective gas cleaning systems. These gasifiers have been put to use for
large-scale power generation.
Several commercial manufacturers have obtained license from I.I.Sc. Bangalore for
manufacture of downdraft gasifiers based on I.I.Sc. technology. Some of these manufacturers
are M/s Bio residue Energy Technology Pvt. Ltd., M/s Evergreen Power Ltd., M/s Arrya Hi-
Tech Energy and M/s NetPro Renewable Energy (India) Pvt. Ltd. More than 25 gasifiers
based on I.I.Sc. Technology have been installed in India and abroad for diverse applications
such as thermal, village electrification, water pumping applications, industrial applications
(captive electricity generation) and research and educational purpose. SPRERI has also
developed gasifiers for different energy requirements. These gasifiers are adopted for
groundnut shells and installed in the ceramic industries for baking of raw items at about 900-
1300°C. Due to these installations, the oil consumption of the industry has reduced by almost
70%. M.K. University at Madurai has also made vital contributions to development of
gasifiers suitable for industrial applications. The major achievement of this centre is in terms
of adoption of the gasifiers for high temperature applications typical of ceramic and
aluminium industries. Noteworthy R&D efforts of technology development have also taken
place in industrial sector. The biomass Gasifier based thermal and electricity generation has
tremendous growth potential in the country. MNRE has offered attractive financial support
in terms of capital subsidies (Rs. 125,000 per 300 kWh for thermal application and Rs.
150,000 per 100 kWe for electrical applications in 2006) for gasifier installations in India.
14
1.10.6.3 Applications of gasifier
1.10.6.3.1 Generation of Producer gas
Most gasifier in commercial operation today are used for the production of heat,
rather than fuel for internal combustion engines, because of the less stringent requirements
for gas heating value and tar content. The fundamental advantage of a gasifier close coupled
to a burning system is its ability to produce higher temperatures than can be achieved with
conventional grate, combustion, liable to slagging problems at such temperatures, and in
consequence its enhancement of boiler efficiency and output.
All types of gasifier can provide producer gas for combustion purposes, but for the
sake of simplicity up-draught gasifier are preferred in small systems (below 1 MW thermal
power), while fluidised bed gasifier are appropriate in power ranges above this level. Most
conventional oil-fired installations can be converted to producer gas.
15
kW power range. There is some support for this in the prices charged for vehicle gasifier
systems during the Second World War. It is not clear however if the difference of about
twenty percent was caused by the difference in technology or was a result of better organized
production or simply a matter or different profit margins.
1.10.6.3 .6 Micro scale applications (1 - 7 kW)
This is the range Used by small and medium farmers in developing countries for
providing power for irrigation systems. Equipment must be transportable, cheap, simple and
light in weight. It is quite possible that only small locally manufactured charcoal gasifiers
will be able to meet the above requirements.
Chapter 1 gives the detail introduction about the power scenario, various renewable
energy sources, importance of biomass gasifier power project for rural area.
Chapter 2 consist of brief discussion on biomass properties, performance of different
biomass reactors and performance and emission characteristics of engine with producer gas
are discuss in this chapter.
Chapter 3 consists of general principle of biomass gasification based electricity
generation system, different reactor designs, gas cooling and cleaning system and engine
generator system.
Chapter 4 details the methodology for performance analysis of biomass gasifier engine
system and cost estimation.
Chapter 5 details the performance analysis of biomass gasifier installed at RET park,
AHEC and results and discussion of present work.
Chapter 6 presents the conclusion of present study.
17
CHAPTER 2
LITERATURE REVIEW
Gasification means converting a solid fuel into a gaseous fuel without leaving any solid
carbonaceous residues. Gasifier is essentially a chemical reactor where various complex
physical and chemical processes take place. The solid fuel is converted by a series of
thermochemical processes like drying, pyrolysis, oxidation, and reduction to gaseous fuel
producer gas. This gas can be used for generation of motive power in existing engines. Spark
ignition engine can entirely run on producer gas but in diesel engine it can be used with
diesel. There are different types of gasifiers which are classified according to the direction of
gas flow such as updraft gasifier, downdraft gasifier, cross draft gasifier. Downdraft gasifier
produces gas containing less amount of tar as compared to the other type of gasifier. In down
draft gasifier air enters at combustion zone and the gas produced leaves near the bottom of
the gasifier. In this type of gasifier tar produced from descending fixed bed have to pass
through reaction zone where mostly they have cracked and gasified. These gasifiers are
suitable for woods and agricultural wastes.
In the downdraft gasifiers air enter through radial tuyers. The partial combustion of
wood takes place and hot gases proceed downwards through the firebox construction. The
throat forces the raw gases pass through high temperature zone where most of the unburnt
pyrolysis products are cracked in to gaseous hydrocarbons and thus clean gas is produced.
Different reactions occur in the gasifier for producing producer gas such as Water shift
reaction, Boudouard reaction, methane reaction. In the oxidation zone the oxygen in the air
stream blast reacts with the carbon in the fuel to reduce carbon to form hydrogen and carbon
monoxide. The Carbon dioxide coming from the oxidation zone is also reduced to carbon
monoxide in the reduction zone. The final gas composition relies on water gas shift reaction
18
Parikh et al. reported on the performance of a downdraft gasifier engine system. The
biomass used was leuceana leucocephala. Proximate analysis (dry basis) reported was as
follows; volatile matter 79.9%, fixed carbon 18.9% and Ash content 1.13% [7].
Talib et al. reported the proximate analysis and heating value of the Eucalyptus as
follows; Volatile matter -73.8%, Ash content -5.54%, Fixed carbon -16.1% and calorific
value -22.0 MJ kg" I [8].
Table 2.1 Proximate analysis of Eucalyptus, Leuceana leucocephala and Acacia [91
Jain selected twenty six perennial species growing in their natural habit in central India
and sixteen indigenous & exotic pinus species from the Himalayan region at Kalika for
screening fuel wood properties such as calorific value, density, ash silica, moisture, nitrogen,
volatile matter and fuel wood index and suggested ten perennial hard woods and four soft
wood species as desirable, which have good fuel wood properties [10].
Geyer et al. analyzed the characteristics of silver maple (Acer saccharinum) for use as
an energy or fibre feedstock. Observed calorific value 18.26 kJ g' and specific gravity 0.44,
green volume of silver maple were similar to those of other maples. Its fibre length was
relatively short 0.74 mm. Ash content was 0.40%. Air-blown gasification of whole-tree
silver maple chips in a downdraft gasifier produced a low energy gas 3.7-4.4 MJ m 3. Trials
with dry chip rates of 88 and 127 kg h"1 resulted in an average gas-to-feed mass ratio of 3.0
and an average char yield of 2.9% of the dry wood fed. Oven-dry biomass yields were 11.1 t
ha' annually at 7000 tree ha"1[11].
Gangde et al. determined the physical properties, proximate analysis and heating
values of babool (Acacia nilotica) wood without bark, subabool (Leucaena leucocephala)
19
roundwood with bark, safflower (Carthamus tinctorius) residue briquette and tur (Cajanus
caj an) stalks were studied. Moisture content was below 10% in all four fuels. Babool wood
had the highest bulk density and volatile matter as 0.73 t m 3 and 83.63%, respectively.
Subabool had the greatest heating value 18.68 MJ kg' LHV and least ash content 1.6% than
rest of the fuels. Safflower residue briquette had the highest ashcontnt 14.82% and lowest
value of fixed carbon 9.1% [12]. GTRA
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2.1.2 Performance of various Gasifiers
Date................
Bhattacharya et al. conducted experiment on tw wood ga on and attempts
• ROO ,
to reduce the tar content of the gas. Increasing the wood-chip re content resulted in an
increase in CO2 and H2 but decrease in the CO concentration without significantly affecting
the tar content in the producer gas. For a particular primary air flow rate, an increase in the
secondary air flow of the two-stage gasifier resulted in a decrease in the tar content and the
CO2 and H2 concentrations while the content of CO increased. A charcoal gasifier and a
floating-drum gas-storage system were coupled to a two-stage wood gasifier. The tar content
of the product gas was in the range of 19-34 mg Nm3 for a charcoal gasifier coupled to a
two-stage wood gasifier. With a floating-drum gas-storage system and a 3.5 h retention time,
the tar content was reduced to 9.24 mg Nm3, which is 85% less than that obtained by using a
two-stage wood gasifier alone[3].
Patel and Rao investigated a 20 kW open core throatless down draft rice husk gasifier.
The following results were discussed Patel, S.R. and Rao, C.S. 1993[13].
Table 2.2 Performance analysis of open core throatless downdraft rice husk gasifier[33]
Avg. rice husk consumption kg/h 17-30
Combustion zone temperature C 750-850
Calorific value of gas kcal Nm-3 1000-1100
Cold gas efficiency % 50-60
Avg. pressure drop across the gasifier mm of water 40-55
Specific gasification rate kg m- h- 90-150
Average tar content after gas clean-up unit mg Nm 330
Average particulate content after gas mg Nm 3 39
Ash content % 20
Unburnt carbon % 10-15
OR
Mukunda et al. developed an open core reactor with cooling and a filtering system
along with a blower and a burner. They investigated the gasifier on wood chips (causuarina)
of 50-70 mm length and about 25mm lateral size with a mixture of 50% of the above size
along with small twigs of 1-10 mm diameter and 25-75mm length with 5% sawdust. The
moisture content of the wood chips was in the range of 10-12%. They reported the gas
composition as CO=17%, H2=20%, CH4=1.5%, CO2=14.5% with cold gas efficiency of
78% [14].
Arpakorn studied the corn drying by corncob gasifier. The drying system consists of
gasifier system, hot air equipment, blower and drying room. In the gasifier, rate of corncob
burning was so generated 31.16 kg h-1 and the air mass flow rate was equal to 50.6 kg h1.
The producer gas contained 18.44, 0.08 and 0.27 percent by volume of CO, H2 and CH4
respectively. The producer gas has low heating value about 2,457.61 kJ m -3. The drying of
1000 kg corn from initial moisture content of 21.72 % wb. to 15 % wb. was completed in 8 h
of continuous drying time, the hot air temperature (under the drying grate) was 107.5 °C and
mass flow rate was 1,114.41 kg h- ' Thermal efficiency of the gasifier system and dryer were
88.15 and 18.06 % respectively. The total thermal energy consumption was about 21.59 MJ
kg1 H2O evaporation, of which 20.38 MJ kg- ' H2O evaporation is for thermal energy from
producer gas and 1.21 MJ kg"' evaporation is for thermal energy from blower. The cost of
drying was 9.4 Baht /kg H2O evaporation. The recovery period of the system was estimated
to be 4 years by assuming the operating life of 10 years for this system [15].
Sada Siva Rao developed a bagasse based gasifier of having an inner shell of 700 mm
diameter, 1860mm height and fitted with a forced air distribution system. The biomass
feeding system was having a hopper and a screw auger and a burner was fabricated for the
gasification of bagasse. The reactor could hold 30 kg which was found to be consumed in 10
to 15 minutes giving a biomass consumption rate of 120-180kg h-'. He reported the average
gas composition as follows: CO=17.5%, H2=16.8%, 02=3.6%, HC=5800 ppm and the
balance was N2. A flame of nearly 3m height having 700°C was obtained [16].
Gabra et al. reported that gasification of cane trash in the cyclone gasifier. The cane
trash powder is injected into the cyclone with air as transport medium. The gasification tests
were made with two feeding rates, 39 and 46 kg h1 at two equivalence ratios of 0.25 and
0.20 and the gasification temperature ranging from 820°C to 850°C. It was found that the
heating value of the producer gas is in the range of 4.5-4.8 MJ Nm3 (dry gas), which is
sufficient for stable gas turbine combustion [17].
21
Dogru et al. studied that a pilot scales down draft gasifier to investigate gasification
potential of hazelnut shells. A full mass balance was reported including the - tar production
rate as well as the composition of the produced gas as a function of feed rate. Additionally,
the effect of feed rate on the CV composition of the product gas and the associated variations
of gasifier zone temperatures were determined with temperatures recorded throughout the
main zones of the gasifier and also at the gasifier outlet and gas cleaning zones. Pressure
drops are also measured across the gasifier and gas cleaning system because the produced
gas may be used in conjunction with a power production engine when it is important to have
low pressure drop in the system. The quality of the product gas was found to be dependent
on the smooth flow of the fuel and the uniformity of the pyrolysis. The optimum operation of
the gasifier was found to be between 1.44 and 1.47 Nm3 kg1 of air fuel ratios at the values
of 4.06 and 4.48 kg h'1 of wet feed rate which produces the producer gas with a good CV of
about 5 MJ m 3 at a volumetric flow of 8-9 Nm3 h-1 of product gas. It was concluded that
hazelnut shells could be easily gasified in a downdraft gasifier to produce good quality gas
with minimum polluting by-products [18].
Yin et al designed a circulating fluidized bed (CFB) biomass gasification & power
generation system (BGPG) for rice husk and installed to power a rice mill with a capacity of
150 t d4 . The system consists of a CFB gasifier, a gas cleaner (including an inertial
separator, a cyclone separator, a venturi and two water scrubbers), and power generation
subsystem, in addition to a wastewater treatment system. It is found that the system can be
operated stably within the temperature from 700 °C to 850 °C, and its optimal condition was
22
reached when the workload is increased above 800 kW. The main performance indices are:
capacity: 1500 kg h-1 , gasification efficiency 65%, rice husk consumption 1.7-1.9 kg kW"l h-',
total efficiency about 17%. The reliability of the BGPG system has been proven through two
years of operation (about 10,000 h) [20].
Fang et al. (2004) tested 1 MW thermal gasification system based on rice husk, in
which it was found that the ignition temperature was only 340 °C, much lower than coal. The
gas velocity and air split had great effect on rice husk combustion. At proper operating
condition, the rice husk combustion efficiency reached 97%, and the carbon content in fly
f 200-to 800 ppm, SO2 ranged
ash was between 3 - 8%, whereas CO emissions vari om—
ed
from 50 to 100 ppm and NOx ranged from 150 to 220 ppm [21].
Das designed downdraft gasifier to operate 5.25 kW diesel engines on dual fuel mode.
Engine was tested on diesel as well as on dual fuel mode (producer gas and diesel) at four
speeds (1500 to 1800 rpm) and six different loads. Wood chips, corn cobs and pigeon pea
23
stalks were used as feedstock. The maximum amount of diesel substitution with different
biomass fuels was varied from 70 to 82% [22].
based system were reported as CO 0.6 to 2.2 g MJ , NOx 0.3 to 0.7 and particulates less
-1
than 0.15 g MJ . Lower level of NOx due to lower peak temperature in the gaseous flame
was observed as compared fossil fuel [24].
Ghosh et al. studied the performance of the first commercially run largest biomass
gasifier based power plant in India i.e. Gosaba power plant West Bengal. Substitution of
diesel by producer gas first increased with the increase in engine load, reaches maximum at
58% load condition, then decreases at a lower rate. The unit cost of electricity generation
was Rs. 4.27 in the 2004 and Rs. 4.15 in 2012 exclusive of the capital cost. However, the
same was estimated as Rs.9.35 and Rs. 4.65, respectively, with including capital cost.
Exhaust gas was analyzed and found that system emits 1743 g of CO2, 1.6 g of SO2 and 3.4 g
Ramadhas et al. studied the performance and emission characteristics of 5.5 kW engine
in dual fuel mode using producer gas produced from coir pith and diesel and compared with
diesel alone. Engine performance was studied for different air gas mixtures applying varying
load. Break thermal efficiency (BTE) of engine operated with rubber seed oil and coir pith
producer gas mixture was lower than diesel and coir pith producer gas. BTE of engine
operated with rubber seed oil alone was less than that of diesel but it was higher than the
BTE of engine operated with rubber seed oil and coir pith producer gas. The high amount of
producer gas reduced fresh amount of air entering in to the engine hence at high producer gas
flow rate the BTE decreased. Poor atomization of rubber seed oil low calorific value and
incomplete combustion were other causes of reduction in BTE of engine in dual fuel mode.
Specific energy consumption in dual fuel mode of operation was found to be higher than that
of diesel alone at all operating conditions. At higher percentage of producer gas flow,
specific energy consumption was found to be higher this happened due to poor atomization
and less air supply which lead to incomplete combustion.
The pilot fuel replacement was found to be around 30% due to use of producer gas.
Saving of diesel was higher than that of saving of rubber seed oil this is due to high calorific
value of diesel. Saving of pilot fuel reduce at higher loads because of lower calorific value of
producer gas and also incomplete combustion. Carbon monoxide emission of engine with
pilot fuel and producer gas was found to be higher than that of engine when operated with
diesel alone. This was due to the incomplete combustion in dual fuel mode. The CO
emission in rubber seed oil was less than diesel alone. And more CO was observed at Rubber
seed producer gas than diesel producer gas mixture. The higher producer gas flow to engine
increases CO2 emission while CO2 emission increases with increase in load. It was also found
that CO2 emission in producer gas-rubber seed oil operation was slightly more than that of
25
producer gas-diesel operation. Smoke density increased with engine load. Rubber seed oil
and coir pith mixture having higher smoke density as compared to other fuels. Exhaust gas
temperature of rubber seed oil fueled engine was found to be higher than diesel engine.
While Exhaust gas temperature was found to higher in duel fuel mode with oil than dual fuel
mode with diesel [27].
On the basis of literature review it is conclude that different biomass material having
different physical and chemical properties the heating value of different biomass material are
studied. Eucalyptus having the good gasification properties. So Eucalyptus is used for the
experimental purpose, It is also studied that the different types of reactors are used for
gasification purpose but for power purpose the downdraft gasifier is used because it generate
less tar compare to other reactors which is suitable for engine application purpose. It is also
found that the most of the experiments are carried out on duel fuel engine as a substituate of
diesel and less work is carried out on 100 % producer gas engine.
26
CHAPTER 3
3.1 GENERAL
Access to quality, reliable and affordable energy is critical for promoting economic and
social development in rural areas. The energy situation in rural India is characterized by low
quality of fuel, low efficiency of use, low reliability of supply and limited access leading to
lower productivity of land, water and human effort, ultimately leading to low quality of life
and environmental degradation. First, dependence on biomass (fuel wood, crop residue and
cattle dung) and traditional cook stoves with low efficiency which emit smoke into kitchen,
leads to low quality of life for most rural women. Secondly, dependence on kerosene and
wick lamps for lighting with uncertain supply of the fuel leads to low quality and intermittent
lighting.
Thirdly, dependence on centralized grid electricity supply to low-load rural situations
is characterized by fluctuating voltage, unreliable supply and shortage of power in most parts
of rural India. Dependence on coal-based electric power plants (accounting for 70% of power
generation) is leading to environmental degradation; local (land degradation), regional (air,
water and soil pollution) and global (greenhouse gas build-up leading to climate change).
There is a realization on the need to search for decentralized and renewable energy-based
options to meet the rural energy needs in a sustainable way. Among all the renewable energy
sources, biomass is the largest, most diverse and readily exploitable resource. In India,
among the renewable energy options, bio energy technologies have been promoted for
meeting rural electricity needs. Further, amongst the bio energy technologies, the biomass
gasifier option for meeting the rural electricity needs of domestic, Agricultural pumping and
rural industrial (such as milling) activities is shown to have a large potentiall.
Biomass gasification involves partial combustion of biomass under controlled air
supply, leading to generation of producer gas constituting the combustible gases H2 (20%),
CO (20%) and CH4 (1-2%). The energy value of producer gas is about 5.0 MJ/m3. The
producer gas can be used as fuel for internal combustion engine for mechanical and electrical
applications. [28]
27
3.2 PRINCIPLE OF GASIFICATION
Biomass gasification is basically conversion of solid fuels (wood, wood waste,
agricultural residues etc) into a combustible gas called producer gas. The process is typically
used for various biomass materials and it involves partial combustion process occurs when
air supply is less than adequate for the complete combustion of biomass [29].
3.2.1 The advantages of gasification are
a. It converts the low quality fuel that is inconvenient to use into high quality
convenient combustible gaseous fuel. Such conversion is at relatively very high
efficiencies and result on total convenience and process control.
b. Almost all environment pollution associated with biomass use can be eliminated. It is
environment friendly and reduces the threat of global warming.
c. Both initial investment and also the cost of energy production are just about the
lowest among all known alternatives as it is based on locally available resources with
reasonable price stability.
d. As this is a renewable technology there are a number of incentives available from
government.
3.2.2 Gasification Process
The essence of gasification process is the conversion of solid carbon fuels into carbon
monoxide by thermo chemical process. The gasification of solid fuel is accomplished in air
sealed, closed chamber, under slight suction or pressure relative to ambient pressure.
Gasification process is shown in Fig.3.1 and 3.2
Harsresting Processing
Chopping
Motor
Briquetting Gas
Turbine
Gle wrung
Biomass
Dehydration Boiler
Drying
r:
Fig. 3.2 Conversion of biomass into Producer gas
3.2.2.1 Drying
Biomass fuels consist of moisture ranging from 5 to 35%. At the temperature above
100 ° C, the water is removed and converted into steam. In the drying, fuels do not
experience any kind of decomposition.
3.2.2.2 Pyrolysis
Pyrolysis is the thermal decomposition of biomass fuels in the absence of oxygen.
Pyrolysis involves release of three kinds of products: solid, liquid and gases. The ratio of
products is influenced by the chemical composition of biomass fuels and the operating
conditions. The heating value of gas produced during the pyrolysis process is low (3.5 - 8.9
MJ/m 3).
It is noted that no matter how gasifier is built, there will always be a low temperature
zone, where pyrolysis takes place, generating condensable hydrocarbon.
3.2.2.3 Oxidation
Introduced air in the oxidation zone contains, besides oxygen and water vapors, inert
gases such as nitrogen and argon. These inert gases are considered to be non-reactive with
fuel constituents. The oxidation takes place at the temperature of 700-20000 c.
Heterogeneous reaction takes place between oxygen in the air and solid carbonized
fuel, producing carbon monoxide. Plus and minus sign indicate the release and supply of heat
energy during the process respectively.
29
C+02 = CO2+406 [MJ/kmol]
In reaction 12.01 kg of carbon is completely combusted with 22.39 m3 of oxygen
supplied by air blast to yield 22.26 m 3 of carbon dioxide and 393.8 MJ of heat.
Hydrogen in fuel reacts with oxygen in the air blast, producing steam.
H2+%202=H20+242 [MJ/kmol]
3.2.2.4 Reduction
In reduction zone, a number of high temperature chemical reactions take place in the absence
of oxygen. The principal reactions that take place in reduction are mentioned below.
Boudouard Reaction
Water-gas reaction
C + 2H 2 = CH 4 + 75 [MJ/kmol]
Main reactions show that heat is required during the reduction process. Hence, the
temperature of gas goes down during this stage. If complete gasification takes place, all the
carbon is burned or reduced to carbon monoxide, a combustible gas and some other mineral
matter is vaporized. The remains are ash and some char (unburned carbon). [30]
The oldest and simplest type of gasifier is the counter current or up draught gasifier
shown schematically in Fig.3.3
30
Fig. 3.3 Up draught or counter current gasifier
The air intake is at the bottom and the gas leaves at the top. Near the grate at the
bottom the combustion reactions occur, which are followed by reduction reactions somewhat
higher up in the gasifier. In the upper part of the gasifier, heating and pyrolysis of the
feedstock occur as a result of heat transfer by forced convection and radiation from the lower
zones. The tars and volatiles produced during this process will be carried in the gas stream.
Ashes are removed from the bottom of the gasifier.
The major advantages of this type of gasifier are its simplicity, high charcoal burn-
out and internal heat exchange leading to low gas exit temperatures and high equipment
efficiency, as well as the possibility of operation with many types of feedstock (sawdust,
cereal hulls, etc.).
Major drawbacks result from the possibility of "channeling" in the equipment, which
can lead to oxygen break-through and dangerous, explosive situations and the necessity to
install automatic moving grates, as well as from the problems associated with disposal of the
tar-containing condensates that result from the gas cleaning operations. The latter is of minor
importance if the gas is used for direct heat applications, in which case the tars are simply
burnt.
31
3.3.2 Downdraught or co-current gasifiers
A solution to the problem of tar entrainment in the gas stream has been found by
designing co-current or downdraught gasifiers, in which primary gasification air is
introduced at or above the oxidation zone in the gasifier. The producer gas is removed at the
bottom of the apparatus, so that fuel and gas move in the same direction, as schematically
shown in Fig: 3.4
Feed
Oryir aor►e
.... •-
:;::.::::: :_ :'.. +~ Distillation zone
Hearth zone
Ar __ Air
Reduction zone
~~ ~.~ w~ w ~• ~.r w Orate
Ash pit
On their way down the acid and tarry distillation products from the fuel must pass
through a glowing bed of charcoal and therefore are converted into permanent gases
hydrogen, carbon dioxide, carbon monoxide and methane.
Depending on the temperature of the hot zone and the residence time of the tarry
vapours, a more or less complete breakdown of the tars is achieved.
The main advantage of downdraught gasifiers lies in the possibility of producing a tar-
free gas suitable for engine applications.
32
Because of the lower level of organic components in the condensate, downdraught
gasifier suffers less from environmental objections than up draught gasifier.
Advantages of the system lie in the very small scale at which it can be operated.
Installations below 10 kW (shaft power) can under certain conditions be economically
feasible. The reason is the very simple gas-cleaning train (only a cyclone and a hot filter)
which can be employed when using this type of gasifier in conjunction with small engines.
A disadvantage of cross-draught gasifier is their minimal tar-converting capabilities
and the consequent need for high quality (low volatile content) charcoal.
33
.LII flll+
A design approach aiming at the removal of the above difficulties is the fluidized bed
gasifier illustrated schematically in Fig.3.6
Air is blown through a bed of solid particles at a sufficient velocity to keep these in a
state of suspension. The bed is originally externally heated and the feedstock is introduced as
soon as a sufficiently high temperature is reached. The fuel particles are introduced at the
bottom of the reactor, very quickly mixed with the bed material and almost instantaneously
heated up to the bed temperature. As a result of this treatment the fuel is pyrolysed very fast,
resulting in a component mix with a relatively large amount of gaseous materials. Further
gasification and tar-conversion reactions occur in the gas phase. Most systems are equipped
with an internal cyclone in order to minimize char blow-out as much as possible. Ash
34
particles are also carried over the top of the reactor and have to be removed from the gas
stream if the gas is used in engine applications.
GAS
CYCLO1 E
1T 1
P]GIRCUTA' EEN OF 2f
pp O~O Q FUe
Oapsdo~ •
•
FIULDIZED D •o'd°
~•••
'O_ OQ p
DISTRIBJ'ItJR 04 ° Od
prn vrrl
—
AIR, OXYGEN
OR S"LEAM ASH
The major advantages of fluidized bed gasifiers, as reported by Van der Aarsen and
others, stem from their feedstock flexibility resulting from easy control of temperature,
which can be kept below the melting or fusion point of the ash (rice husks), and their ability
to deal with fluffy and fine grained materials (sawdust etc.) without the need of pre-
processing. Problems with feeding, instability of the bed and fly-ash sintering in the gas
channels can occur with some biomass fuels.
Other drawbacks of the fluidized bed gasifier lie in the rather high tar content of the
product gas (up to 500 mg/m3 gas), the incomplete carbon bum-out, and poor response to
load changes.
Particularly because of the control equipment needed to cater for the latter difficulty,
very small fluidized bed gasifier are not foreseen and the application range must be
tentatively set at above 500 kW (shaft power). [30]
35
3.4 COMPONENT OF GASIFIER BASED ELECTRICAL GENERATION
SYSTEM
The gasifier is usually cylindrical in shape for strength and ease of manufacture. Fuel is
fed by gravity from the upper hopper section into the lower fire zone section. There are three
basic kinds of generator, named from the airflow direction. Down-draught units have "a
restriction around the hearth causing an increase in air velocity and higher operating
temperature which tends to gasify tars which would otherwise be a problem when using
green wood as fuel.
On leaving the gasifier, producer gas must be cleaned of impurities such as soot, ash,
un-burnt fuel dust and tar in order to prevent engine damage. The design and sequence of
components will depend upon requirements of fuel and engine, but must not offer excessive
resistance to the gas flow if engine starvation is to be avoided.
Secondary cleaning, which may follow the cooling section, may be a dry or wet
process. The gas may be filtered dry through sisal, wood, wool, felt, paper, fabric, or close-
set brush bristles, and electrostatic filters are also on the market. In wet filtration, the filter
element is wetted with oil (usually diesel or kerosene) or water. Water is not very effective
against tar but may reduce the incidence of explosions. Wet filtering is also called scrubbing
or washing.
The choice of filters should not be made on technical efficiency alone but rather on
possible operational reliability. Experience with agricultural tractors has indicated that for
example, although modem paper air filter elements may be capable of high efficiency,
the odd hole may cause serious and costly breakdowns in equipment and operations under
practical third world conditions.
36
Generator lectririty
Cooling the gas will increase its density, so allowing a greater charge (by mass) per
cylinder, and exposed piping when cooled will become less of a fire hazard. After the
primary cleaning unit, the gas may then be passed through a radiator unit mounted at the
front of the engine.
The cooler may be by-passed by means of butterfly valve for starting from cold if
condensation is found to clog dry filters. A fine wire gauze or felt cloth placed before the
engine as a "security filter" will clog up and provide warning of failure of the cleaning-
cooling sections when the engine stalls.
Efficient engine operation requires adequate adjustment of the proportion of air and
gas, and the quantity of the resulting mixture reaching the engine. In its simplest form the
valve consists of a Y-piece. The gas enters through one branch, the air from an air cleaner
through the second branch, and the resulting mixture flows through the stem to the existing
engine induction system between the carburetor and the induction manifold. The admission
of air is controlled by a butterfly valve in the air branch.
While the preference would be to use purpose designed gas engines it is possible to use
producer gas as a fuel for either spark ignition (SI) and compression ignition (CI) engines.
However, as producer gas cannot easily be liquefied it has to be introduced by means of a
37
Fig.3.7 Biomass Gasifier System
Cooling the gas will increase its density, so allowing a greater charge (by mass) per
cylinder, and exposed piping when cooled will become less of a fire hazard. After the
primary cleaning unit, the gas may then be passed through a radiator unit mounted at the
front of the engine.
The cooler may be by-passed by means of butterfly valve for starting from cold if
condensation is found to clog dry filters. A fine wire gauze or felt cloth placed before the
engine as a "security filter" will clog up and provide warning of failure of the cleaning-
cooling sections when the engine stalls.
Efficient engine operation requires adequate adjustment of the proportion of air and
gas, and the quantity of the resulting mixture reaching the engine. In its simplest form the
valve consists of a Y-piece. The gas enters through one branch, the air from an air cleaner
through the second branch, and the resulting mixture flows through the stem to the existing
engine induction system between the carburetor and the induction manifold. The admission
of air is controlled by a butterfly valve in the air branch.
37
gas carburetor and is present during the compression stroke for both types of engine. In the
SI engine the gas is ignited (as for petrol) by a high voltage spark but in the CI engine
ignition is achieved by injecting a small amount of diesel into the cylinder at the end of the
compression stroke. Modern gas engines are available which are similar in design to CI
engines (for strength and durability) but use a spark plug or glow plug to provide ignition for
the gas.
Spark ignition engines are cheap, if based on mass-produced automotive engines, and
are simple to operate but are sensitive to changes in gas quality. Little modification is
required to an automotive engine other than changing the carburetor for one suitable for use
with gas and hardening the valves and valve seats. These engines can be operated on 100%
producer gas achieving efficiencies of around 25% at full load but this can fall off rapidly
when operating at part loads.
Consideration also needs to be given to the ignition timing of the engine. Typically
there is a greater ignition delay with producer gas compared with petrol. Therefore the
ignition point (the crank angle at which the spark occurs) of a SI engine is usually advanced
when a gaseous fuel is used to ensure optimum performance.
The CI engine is much more complex to operate and will not work on biogas or
producer gas alone. If biogas were admitted in anything like the Stoichiometric ratio, it could
spontaneously ignite during the compression stroke. The engine would then `knock', run
unevenly, and overheat very quickly. Therefore the gas can only be admitted to the engine at
quite high air/fuel ratios greater than 30:1 (by mass). The exact ratio will be dependent on
the design of the engine and its compression ratio.
Most large, medium and low speed engines normally operate as diesel engines with
an air/fuel ratio of around 30:1 and so it is possible to operate them on 90% gas and 10%
diesel especially if they have relatively low compression rations of around 14:1. Smaller,
high speed CI engines (auto derivative) are normally rated with relatively low air/fuel ratios
of 20:1 and compression ratios of between 16 and 18:1. These engines require much more
diesel fuel injected at maximum load some times as much as 60%. Compression ignition
engines can operate on all ratios of producer gas/diesel oil, which can be desirable when
producer gas production is subject to fluctuations.
Compression ignition engines are more expensive but are less sensitive to changes in
gas quality and have better efficiencies (30 and 35%), which can be maintained through out
regardless of load.
38
Spark and compression ignition engines will require modifications to the valves, valve
seats and carburetor before they can be used with producer gas. The dry nature of producer
gas means that it does not have lubricating properties and therefore valve wear is more likely
to occur. The materials used for the valves and valve seats will need to be modified (i.e.
hardened) or changed to improve wear resistance.
CI engines also require several other major modifications. These include lower
compression ratios, provision of extra cooling to injectors, and the fitting of gas carburetor.
Generally spark ignition engines are less robust than compression ignition engines but
don't need supplementary fuel. Therefore it is common to convert compression ignition
engines to spark ignition as a compromise between robust and reliable operation and to
alleviate the need for supplementary fuels.
3.4.6 Generator
Generator transforms mechanical energy into electrical energy. Now a day's only 3
phase A.C.(Alternating current) generators are used in normal practice. There are basically
two types of generators: namely synchronous generator and Induction generator. The
Induction generator also called as Asynchronous generator based on the super synchronous
speed at which they are operated. Synchronous generators are mostly used for the gasifier
applications.
39
CHAPTER 4
4.1 GENERAL
A process of conversion of solid carbonaceous fuel into combustible gas by partial
combustion is known as gasification. The resulting gas, known as producer gas, is more
versatile in its use than the original solid biomass The effects of air flow rate and moisture
content on biomass consumption rate and quality of the producer gas generated. The
performance of the biomass gasifier system is evaluated in terms of equivalence ratio,
producer gas composition, calorific value of the producer gas, gas production rate, zone
temperatures and cold gas efficiency
Performance of the Biomass gasifier system is depends on the biomass properties,
temperature profile of the reactor, equivalence ratio, these affect the gas composition, and
calorific value and gas production rate.
Performance of th Biomass gasifier is measured in terms of flow rate of the air, and the
gas (using calibrated venture meter), average consumption rate of wood chips, temperature at
the end of reduction zone, at inlate and exit of the cyclone and at the end of the cooling
circuit (using chromel-alumel thermo couples), and power delivered by the engine generator
set, gas composition by Orsat apparatus or gas chromatograph, calorific value using Junker
gas calorimeter.
.Particulates and tar are measured by simple technique which involves the collection of
these on thick cotton wad at about 0.1 meter diameter placed in a circuit at end of cooling
cleaning system for a specific period of time (typically 30-45 minute). The cotton is weight
before and after the test. The difference is taken to be the weight of both tar and particulate
put together. The material deposited on cotton is later dissolved in ethyl alcohol and filtered.
What is left behind the on the filter paper constituents particulate matter and that passing
through a filter paper is tar.
The size fraction of the Wood was directly measured from samples collected from the
industry. The averages of more than 10 samples were taken as size of wood. The diameter
and the height/thickness were also recorded.
41
(b) Moisture content
Moisture content plays an important role in controlling the energy release during the
gasification process. Moisture content was determined by drying known weight of sample in
an open Petri dish in an electrical oven at 103 ± 5°C for one hour until constant weight is
reached by adopting standard procedure [31].
MC = Moisture content, %
The true density of wood was measured individually by measuring the weight and
volume of samples of regular shape. The true density was calculated by dividing the weight
of individual specimen by its volume. The average value of five specimens was taken as the
true density.
The bulk density was determined by weighing the feedstock filled in a vessel of known
standard volume and calculating the ratio of the weight of feedstock to the volume of the
vessel [4]. The average of five trials was reported as the value of the bulk density of feedstock.
To assess the feed stock behavior during thermo-chemical conversion, proximate and
ultimate compositions were determined as per standard procedure. [32]
The proximate analysis included fixed carbon, volatile matter and ash content of the
material. ASTM standards D3172-73 (ASTM, 1977) through D3173-75 and procedures for
volatiles were used [32].
Volatile matter were determined by keeping one gram of air dried and ground sample in
a silica crucible with a lid at 600°C for six minutes and then at 750°C for another six minutes
42
in a muffle furnace. The difference in the weights due to the heating was taken as the total
volatile matter present in the sample.
The dried samples were taken in a silica crucible and heated gradually in a muffle
furnace to 750°C for two hours or more till a constant weight was recorded.
The fixed carbon on percentage basis is calculated by subtracting the sum of percentages
of ash content and volatile matter from 100.
The gross calorific value of the biomass was determined with two methods namely
bomb calorimeter and using Dulongs formula by knowing the ultimate analysis of fuel
i) Bomb calorimeter
The water equivalent is the weight of water which is equivalent in effective heat
capacity to the entire system (Calorimeter vessel containing a specified weigh of water
calorimeter bomb charge with oxygen fuel and water calorimeter and stirrer). Since the
specific heat of water is 1.000 = 0.002 cal/gm in the range 10°C to 40 °C, the water
equivalent is . not required and is never evaluated. It is the effective heat capacity which
should be considered. The effective heat capacity is the heat required to effect unit
temperature rise in the system under the conditions of a calorimeter determination. The
effective heat capacity has a temperature dependence since the specific heats of the
constituents parts of the system vary with temperature 25°C has been chosen as the reference
temperature because of its use in thermo-chemical calculations and because the specific heat
of water in the range 25°C to 40°C is constant within ± 00002 cal/ g°C.
Accurately weigh in the crucible of the calorimeter about one gram of the air/dried
material ground to pass through IS Sleeve 20 (2110 mcrons)
Stretch a piece of the firing wire across the electrodes within the bomb tie 15 cm.
Length of sewing cotton around the wire place the crucible in position an arrange the loose
ends of the thread so that they are in contact with the material use the same mount of thread
in each determination. Introduce into the body of the Bomb two milliliters of distilled water
Resemble the bomb, screw home with the fingers, finally tightening it as necessary, avoiding
43
excessive pressure. Charge the Bomb slowly with oxygen from a cylinder to a pressure of 25
atmospheres without displacing its original air content close the valve effectively, using as
little pressure as possible, and detach the bomb from the oxygen supply.
Weight into the calorimeter vessel a quantity of water sufficient of submerge the cover
of the bomb to a depth of at least two centimeters leaving the terminals projecting. Use the
sam weight of water in all tests. Transfer the calorimeter vessels to the water jacket; lower
the bomb carefully into the calorimeter vessel and, having as curtained it to gas-tight through
a switch for subsequent firing of the charge. Adjust the stirrer place the thermometer and
covers in position and start the stirring mechanism, which must be kept in continuous
operation at a constant speed during he experiment. After an interval of not less than ten
minutes, read the comparative to 0.0001°C /- readings for five minutes at equal intervals of
not more than one minute, tapping the thermometer lightly during 10- seconds prior to each
reading. If , over a period of five minutes, the average deviation of the individual values of
the rate of change of temperature isles than 0.00072 °C per minutes, close the circuit
momentarily to fire the charge and continue the observations of the temperature at intervals
of similar duration to those of the preliminary period. If the rate of change of temperature is
not constant within the limit, extend the preliminary period until it is constant. In the chief
period which extends from the instant of firing until the time after which the rate of change
of temperature again becomes constant, take the earlier readings to the nearest 0.01°C since
it will not be possible to take the earlier readings to 0.001°C. Resume the readings to this
precision as soon as possible.
Determine the rate of change of temperature in the after period (which follows the
chief period) by taking reading at 1 minute interval for at least five, preferably ten minutes.
CVC=W xT
M
Where,
W = Water Equivalent of Calorimeter (2218 Cal/ °C)
T = Rising in Temp in °C (Temp Difference)
M = Weight of Sample (gm)
CV = Calorific Value (kcal/kg)
ii) Dulongs formula method
The gross calorific value of samples was found out by Dulongs formula.
Where C, H, 0 and S are fractional composition of elemental carbon, hydrogen, oxygen and
sulphur respectively
Allow the gas to pass for two or three revolutions as indicated by the flow meter. Then
light the burner and adjustment the air regulator sleeve and the gas tap to get a non luminous
flame. Clamp the burner keeping it to the top most position. Then adjust the flow of water to
get a temperature difference of 12 to 15°C between the water inlet and outlet temperatures.
This is important. If the flow of water is less than the required, there will be a high
temperature difference and the water may escape as steam. So the water flow is to be
adjusted in such a way that there will not be formation of steam.
Allow the water outlet thermometer to indicate a steady temperature which may take
about 20 to 30 minutes. Keep the 2000 ml measuring the jar beneath the swinging water
outlet tube, and simultaneously count the number of revolutions made by the gas flow meter
pointer i.e. to find the volume of gas consumed during the test period. When the pointer has
made 2 to 3 revolutions swing the water outlet back to waste. Also immediately note the
temperatures of water inlet outlet as well as gas flow meter.
Keeping the water and Gas flow meter same repeat the experiment thrice or four times
and take the average of the readings and calculate the calorific value of the gas using the
following formula.
45
Where,
C.V. = Calorific value of the gas in kcals per Cu. metre
Vw = Volume of water collected during the test period, litres
Vg = Volume of gas burnt during test period, litres
t2 = Average water outlet temperature °C
ti = Average water outlet temperature °C
The actual air fuel was determined based on the assumption of equivalence ratio. Air
equivalence ratio (E.R) is the ratio of actual air consumed during reaction to the stoichiometric
air required for combustion.
For gasification, the equivalence ratio to be adopted varies from 0.2 to 0.4. Here average
of 0.3 was taken for design purpose.
The producer gas obtained from gasifiers contains many impurities, with ash and tar
being the main impurities. The cyclone separator are usually unable to remove particulate
impurities below 10 mm. Removal of finer particles can be achieved using filter bags,
sintered ceramic candles or metallic candles. However, depending on the operational load
these devices may clog due to soot and/or tar adhering to ash particles. Wet scrubbing of gas
is a common technique used for removal of particulate matter. Various wet scrubbing
techniques include spray towers, centrifugal spray towers, packed bed column scrubbers,
ejector venture scrubbers and free jet washers. Effective removal of tar has been a principal
problem in producer gas cleaning. Tar mainly comprises of condensable aromatics and
it
polyaromatics. If the gas is to be used in engines or turbines, the tar removal is utmost
essential as the condensation of taro mechanical components moving with high speed can
cause mechanical instability. The principal tar components are toluene, naphthalene and
phenol with many other aromatics comprising of _up to seven benzene rings as secondary
components. [33]. The primary methods of tar removal includes (1) optimization of gasifier
operating conditions in terms of air ratio, bed temperature and sufficient residence time; (2)
use of bed additives or catalysts (such as nickel based catalysts, calcined dolomites,
magnesites, zeolites, olivine and iron catalysts) that act as tar reducers; (3) modification of
Gasifier design, i.e. splitting the gasifier into two stages — pyrolysis stage and reduction
stage. The secondary methods of tar removal consist of physical or chemical treatment such
as (1) either thermal or catalytic cracking of tar downstream of the gasifier and (2)
mechanical removal of tar using cyclone separator and baffle/ceramic/fabric/ electrostatic
filter. Sometimes a multi-stage process is used for secondary gas cleaning.
4.6 GAS PRODUCTION RATE AND AIR FLOW RATE IN THE SYSTEM
The flow rate of producer gas was measured by fitting orifice meters. The head
developed across the orifice plate was measured by a U-tube manometer and the flow rate
was calculated using the formula
Gas flow rate=Ca Ap K
gh P Ps—Pg
m
Where,
Q=AxV
where,
Q — Air flow rate, m3 s-I
A — Area of air inlet pipe, m2
V — Velocity of air at inlet, m s4
Low temperatures (upto 300° C) can be visually indicated with mercury thermometers
or bimetallic dial thermometers. Alternatively thermostat sensors can be used in this
tepreture range to provide an electrical signal that can be used for automatic control purpose.
Pressure drop may be measured routinely across the gasifier bed, the orifice plate folw
meter, the gas clean up system. The pressure within the gasifier will be close to atmospheric
pressure and generally measured in centimeters of water column. Pressure drop and differtial
pressure can be measured by U tube manometer filled with colored liquid.
49
4.9 METHOD FOR CALCULATING GASIFIER EFFICIENCY
(CV)B [kcal/kg]
Where,
Ratio of the output rate [in terms of the energy content of the cold gas] to the
Energy input through biomass consumption rate.
(CV)B [kcal/kg]
The performance of the gasifier was evaluated in terms of its electrical efficiency
which included biomass consumption rate, heating value of wood, generated voltage and
current.
50
It is the ratio of energy output to the energy input. The gasifier efficiency of the system
was calculated as follows:
Energy output
x 100
~ g T Energy input
Energy input
The energy input (Q;) to the gasifier is obtained by multiplying the heating value of
feedstock by the feed stock consumption rate.
Energy input (Q;) = F x HF
Where,
F = Feed stock consumption rate
HF = Heating value of fuel
Energy output
The energy outputs (Q0) consists of voltage and current gentared, and generator power
factor.
Where,
V = Voltage
I = Currant
COS 0 = Power Factor.
Eo = P(8760 * CUF)
51
Where
E0 = Annual delivered electricity output
P = Rated Power Output
CUF = Capacity Utilization Factor
= Ac
LUCE Eo
Total annualized cost can be estimated by taking into consideration the contributions
of the capital costs of subsystems of Biomass Gasifier Power Project (BGPP) through
respective capital recovery factors based on their useful lives and interest rate, annual
52
operation and maintenance costs of the different sub-systems of the BGPP and the cost of
fuel used. The contributions of capital cost (ACc), operation and maintenance cost (ACo&M)
and cost of fuel (ACF) to the total annualized cost can be estimated using the expression
Where Rcw, Reg and Rg, respectively, represent the capital recovery factors for civil
works, engine—generator set and gasifier and it can be calculated on the basis of interest
rate(d)and useful lifetime (T).The capital recovery factor (R),
_ d(1 + d)T
R (1+d)T-1
ACo&m=Cg*mg+Ceg*meg+Ccw*mcw+8760*CUF*ml*n
Where,
mcw = The operation and maintenance costs of civil works as fractions of capital
cost.
meg = The operation and maintenance costs of engine generator as fractions of
capital cost.
mg = The operation and maintenance costs of gasifier as fractions of their e capital
costs.
ml and n = represent the manpower wage rate and number of manpower required for
Operation and maintenance.
53
CHAPTER 5
PERFORMANCE ANALYSIS OF BIOMASS GASIFIER INSTALLED
AT RET PARK, AHEC
The gasifier for electricity generation is installed in Renewable Energy park Alternate
Hydro Energy Centre in IIT, Roorkee campus. is manufacture by MIS ANKUR Scientific
Energy Technology Pvt.Ltd. Biomass gasifier (GAS 4) coupled to gas engine genset (7.5 kW
capacity duly modified to operate in 100% producer gas mode) to give the gross output of
about 5kW. The performance analysis of this biomass gasifier- system was carried out with
respect to the different loading condition.
5.2 System Description
A downdraft biomass gasifier (5kW) Power generating system is shown in Fig.5.1.It
consists of Cylindrical hopper, passive filter, safety filter, 100% producer gas engine and
generator.
6~!
5.2.1 Gasifier
Gasifier used in this study was a downdraft gasifier. Air was supplied through air
nozzles and introduced at the combustion zone. Wood chips with size of 25 mm x 30 mm
were used as feedstock. The producer gas was formed inside the gasifier due to incomplete
combustion of wood and was forced to pass through a high temperature zone at the throat so
that most of the unburnt pyrolysis products were cracked in to gaseous hydrocarbons, and
system produced relatively clean gas. The specifications of gasifier are shown in Table 5.1
Ash storage and removal Storage below the grate in the reactor &
Removal manual in batch mode
Table 5.1 shows the specification of biomass gasifier. Gasifier temperature reach up
to 1100°C so that completely tar cracking is obtained. Wood is used as a feedstock material.
55
5.2.3 Cleaning unit
Primary and secondary filters are used for cleaning of gas.Primary filter consisted of
rice husk and cotton wool to remove course impurities from producer gas. A fabric filter was
used in the secondary filter to remove fine particles from the producer gas.
5.2.4 Engine Generator unit
Biomass gasifier (GAS 4) coupled to engine genet (7.5 kW capacity duly modified to
operate in 100% producer gas mode) to give the gross output of about 5kW. The
specifications of engine-genraor are as shown in Table 5.2.
Engine -Genset
Rated output 5 kW
Engine capacity 7.5 kW
Gasifier start-up power Through battery
Engine start-up Through battery
Specific biomass Consumption Less than 1.5 kg/kWh
RPM 1500
Table 5.2 shows that engine having the power capacity 7.5kW and generator having
the gross output of 5kW.In gas engine the specific biomass consumption is 1.5 kg/kWh.
Staring of engine is through battery.
Performance analysis of 5kW biomass gasifier engine generator system is carried out in
terms of different load condition, Overall efficiency is calculated and also the biomass
consumption rate is calculate at different load condition.
Before testing the performance of gasifier, properties of feed stocks were tested in
terms of its physical and chemical properties required for combustion. The following
properties have been considered for performance analysis of biomass gasifier system.
56
5.3.1.1 Properties of feedstock
Physical and thermal properties of feed stock influence the operation of the thermal
system to a great extent. Physical properties control the flow behavior while the chemical
properties are important to understand how the reactions proceed. The physical properties
include size fraction, moisture content, bulk density and true density. The proximate and
elemental compositions are the chemical properties. Their determination is important to
calculate the associated parameters such as air requirement for proper gasification and reactor
size [35].
The average bulk density of Eucalyptus is determined in the lab and found as 410 kg
m 3 while average true density was 820 kg m 3, whereas the average calorific value of
Eucalyptus is 4404 kcal kg'.
It is seen that from Table 5.3 eucalyptus contains the more volatile matter it indicate
that it having good gasification properties calorific value of eucalyptus is determined with
help of bomb calorimeter and it is found that 4404 kcal kg' .The ultimate analysis of
eucalyptus is given in Table 5.4
Elemental composition, %
57
5.3.1.1.2. Stoichiometric air analysis for wood chips
02 0.428 -0.428 -- --
= 1.345 kg / kg of wood
= 0.463 5 kg of H2O
3 17.4
3.5 20.3
4 23.2
4.5 26.1
58
Stoichiometric air requirement depends upon the elemental composition of the fuel.
In the case of wood chips Stoichiometric air requirement was 5.80 kg per kg of wood.
Table 5.8 shows that at different load conditions the biomass consumption is
increases. It is also observed that at no load condition gasifier shows constant reading while
applying the load initially it consumes more wood after gives constant reading.
En 2.53
z
E 1
.2 0.5
0
0 1 2 3 4 5
Load (kW)
59
Fig. 5.2 shows that biomass consumption rate of gasifier with different loading condition are
has to be done by weighing the feedstock fed into the gasifier and noting down the time of
consumption in the reactor. It is observed that biomass consumption rate at no load, 1 kW,
2kW,3 kW, and 4kW load conditions are 1.5,3,3.5,4,4.5 kg/hr respectively. It is also
observed that at no load condition gasifier shows constant reading while applying the load
initially it consumes more wood after gives constant reading.
Power output is calculated in terms of generated voltage and currant at different load
condition as shown in Table 5.9.
Table 5.9 shows that with increase in electric load it generate more power initially
and after that power drop start. At 1kW load generator generate 1.44 kW power and as we
increase load upto 2kW it generate 1.79kW power.The maximum power generate is
2.88kW at 4kW load conditin.variation of elecrical output with different load condition as
shown in Fig.5.3.
Electrical Output
3.5
3
2.5
I 2
1.5
0.5
0 1 2 3 4 5
Load (kW)
Z1
Fig.5.4 shows that with increasing the electrical load by applying electric heater of 1kW
to 4 kW initially it generate more watts after it gives smaller variation in generation voltage of
system decreases with increase in load.
From the power input and power output the overall efficiency is calculated and it is
found that maximum efficiency at 4kW load is 12.5 %.
From Table 5.10 it is observed that the maximum efficiency is obtained is 12.5% at
4kW load. Variation of efficiency with respect to different load condition is shown in
Fig.5.4.
Overall Efficiency
14
12
10
U_ 8
w 6
L 4
Q1
2
0
0 1 2 3 4 5
Load (kW)
Fig. 5.4 Overall Efficiency of Biomass Gasifier with different load conditions
From Fig.5.4 above is show that overall efficiency of biomass gasifier system operates on 100%
producer gas with different load condition. The maximum efficiency 12.5% is obtained at 4kW
61
load and minimum efficiency at 1kW load is 9.38%.It is also observed that with increasing the
load the biomass consumption rate is also increase it will increase the input power.
rated capacity
Specific biomass consumption in a typical HPG engine BGPP kg/kWh 1.40
at rated capacity
Specific diesel consumption in a typical DF engine BGPP at 1/kWh 0.11
rated capacity
Specific diesel consumption in a typical diesel engine at rated 1/kWh 0.30
capacity
62
Useful life of civil work Years 20
Useful life of engine—generator Years 20
Useful life of biomass gasifier Years 10
As shown in Table.5.12 the energy cost for 100 % producer gas mode of operation,
duel fuel mode of operation and diesel mode of operation. It is observed that the cost of
electricity at 100% producer gas mode is less compared to other system and it is also
observed that the cost of electricity decreases with increase in capacity. The feasibility up to
40kW capacity is calculated and it observed that cost of electricity decreases from Rs.23.44/
to Rs.14.72/kWh in 100% producer gas mode that of dual fuel mode of operation is Rs.26.08
to Rs.17.59/kWh. Cost of electricity is more in diesel mode i.e. Rs.29.36 for 5kW system and
Rs.20.98/kWh for 40 kW system.
As shown in Fig.5.5 the energy cost for 100 % producer gas mode of operation for 5,
10, 20, 30, and 40kW of systems are Rs.23.44/,Rs.19.11/,Rs.16.15/, Rs.15.66/, and
Rs.I4.72/kWh respectively that of dual fuel mode is Rs.26.08,Rs.22.52, Rs.18.84, Rs.18.58,
and Rs.17.59/kWh respectively and diesel mode is Rs.29.36, Rs.25.96, Rs.22.28, Rs.21.93,
and Rs.20.98/kWh respectively.
63
35.00
30.00
25.00
0.00
0 10 20 30 40
From the, cost estimation it is also observed that the initial cost of 100% producer gas
engine is more than diesel engine and duel fuel engine. High cost of 100%producer gas
engine is due to less demand in the market.
Table 5,13 COST DEATAILS OF BIOMASS GASIFIER SYSTEMS
ts.(Lakhs) 1.05 2.625 4.6 6.0 8,0 10.9 1.55 2.6 3.4 4.5 1.2 2.0 3.5 5,0 6,5
3.68 125 2.5 5.0 1.5 10 0.82 1.64 3.3 4.9 6.6
0.46 0.92 1.84 2.76
.ost of fuel(ACf) Rs.(Lakhs)
3.21 5.69 9.76 14.41 18.38 2.86 4.93 8.26 12.2 15.5
2,6 4.36 7.07 10.29 12.9
Total cost Rs.(Lakhs)
21900 43800 65700 87600 10950 21900 43800 65700 87600
knnual delivered electricity 10950 21900 43800 65700 81600 10950
)utput(kWh)
23,44 19.91 16.5 15.66 14.72 29.76 25.96 2228 21.93 20.96 26.08 22.52 16.84 18.58 17.69
Unit cost of electricity Rs.lkWh
CHAPTER 6
CONCLUSIONS
Biomass consumption at different load, i.e.at load 1kW, 2kW, 3kW, and 4kW 1.5, 3,
3.5, 4, and 4.5 kg/hr respectively. It is also observed that at no load condition gasifier shows
constant reading while applying the load initially it consumes more wood.
Overall efficiency of biomass gasifier system operated on 100% producer gas with
different load condition varying from no load to full load are observed. The efficiency at 4kW
load has been found as 12.5% whereas at 1kW, 2kW, 3kW load conditions, the values of
efficiencies has been observed as 9.38%, 10%, and 11.25 % respectively.
Further an attempt has also made to analysis that energy cost for higher capacity of
systems. Energy cost for 100 % producer gas mode of operation for 5, 10, 20, 30, and 40kW
of systems has been found as Rs.23.44/,Rs.19.11/,Rs.16.15/, Rs.15.66/, and Rs.14.72/kWh
respectively. However the values for dual fuel mode are found as Rs.26.08, Rs.22.52,
Rs.18.84, Rs.18.58, and Rs.17.59/kWh respectively and for diesel mode as Rs.29.36,
Rs.25.96, Rs.22.28, Rs.21.93, and Rs.20.98/kWh respectively.
During the experimentation it is also observed that the gasifier engine operate on the
100% producer gas gives the starting problem due to carbon deposition near the spark plug
ignition system, changing the spark plug for every operation are required during the
experimentation.
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