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1 s2.0 S000925091500754X Main PDF
1 s2.0 S000925091500754X Main PDF
H I G H L I G H T S
art ic l e i nf o a b s t r a c t
Article history: In this article, a co-gasification system blending coal and biomass is examined in the Aspen Plus
Received 12 June 2015 environment in terms of energy conversion efficiency (ECE) and exergy efficiency (EE). Although the
Received in revised form percentage of raw wood (RW), torrefied wood (TW) and coal in steam co-gasification is one of the most
31 October 2015
important parameters that affect the gasification process, the addition of CO2 could effectively improve
Accepted 23 November 2015
Available online 11 December 2015
ECE and EE while the steam-to-carbon ratio (S/C) is adjusted at the carbon boundary point (CBP). The
optimum operating conditions such as S/C and CO2 supply ratio, are determined by solving a series of
Keywords: constrained optimization algorithms for maximizing ECE and EE. A combined heat and power (CHP)
Co-gasification system using the maximum waste heat recovery and Rankine cycle is illustrated to assess performance in
Torrefied biomass
terms of power generation and CO2 utilization. The results show that the total power generation by
CO2 utilization
feeding the TW-based fuel blend of 40 wt% TW and 60 wt% coal is increased by 8.43%, as compared to
Carbon boundary point
Combined heat and power that of the RW-based fuel blend of 40 wt% RW and 60 wt% coal. Compared with 100 wt% coal fuel, the
Optimization TW-based fuel can significantly reduce CO2 specific emission by 38.23%.
& 2015 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.ces.2015.11.030
0009-2509/& 2015 Elsevier Ltd. All rights reserved.
202 P.-C. Kuo, W. Wu / Chemical Engineering Science 142 (2016) 201–214
this material compared to those of coal. For example, the major power generation is an important and potential clean coal tech-
properties of raw biomass include (Chen and Kuo, 2011; Sarvar- nology (CCT) that is able to reduce emissions of CO2, the primary
amini et al., 2013; Taba et al., 2013; Thanapal et al., 2014): (1) high greenhouse gas that is responsible global warming. A review of the
moisture content, (2) low calorific value, (3) low energy density, past literature suggests that most of the related studies focus on
(4) high hydrogen-to-carbon (H/C) ratio and oxygen-to-carbon (O/ the type of oxygen-blown (Emun et al., 2010; Zhang et al., 2013),
C) ratio, (5) hygroscopic nature, and (6) a low bulk density, making air-blown (Klimantos et al., 2009; Giuffrida et al., 2013), and a
both transportation and storage costs higher. These properties mixture of steam/oxygen (Lee et al., 2014; Asif et al., 2015) IGCC
mean that raw biomass gasification has a lower conversion effi- systems, while relatively little research has been carried out using
ciency than that seen with coal gasification. In recent years various a mixture of CO2/O2 (Oki et al., 2011; Prabu, 2015). If CO2 is used as
studies have reported that using the combination of coal and a gasifying agent it can not only be converted to carbon monoxide
biomass as a feedstock, in a process known as co-gasification, is as via the Boudouard reaction in gasification, but also reduce the
promising technology for the production of syngas. This process level of CO2 emission into the atmosphere (Prabu, 2015). Fur-
has the advantages of being both economical and environmentally thermore, a number of studies have examined the use of steam
friendly (García et al., 2013; Taba et al., 2012, 2013), and a number and CO2 as a gasifying agent. Castaldi and Dooher (2007) adopted
of researchers have examining blending various types of biomass the Aspen Plus simulator to investigate coal steam gasification
with coal. For instance, Saw and Pang (2013) examined the use of with a CO2 recycle stream to the reformer. They found that the
lignite and wood as a feedstock at various blending mass ratios for addition of CO2 could lead to decreased energy consumption in the
co-gasification. They reported that the H2/CO ratio can be reformer, and thus this is a suitable technique for reducing the
enhanced during co-gasification, and that a H2/CO ratio of 2 (for energy requirements of such systems. Butterman and Castaldi
Fischer–Tropsch synthesis) can be obtained by blending 60% wood (2007) also studied biomass steam gasification by introducing CO2
with 40% lignite. Aigner et al. (2011) reported an increase in via thermogravimetric analysis-gas chromatography (TGA-GC),
hydrogen production and a decrease in CO production with a ris- and found that the existence of CO2 significantly promotes the
ing coal ratio. Furthermore, the concentrations of impurities such production of CO when the operating temperature was beyond
as NH3 and H2S in the gas product have also been found to 700 °C, while the production of H2 is reduced. Prabowo et al.
decrease during the co-gasification process. Howaniec and Smo- (2014) compared the gasification performance under the atmo-
linski (2013) investigated the influence of synergetic effects on the spheres of steam, CO2, and steam–CO2 mixtures. They found that
steam co-gasification process. They reported that the reactivity of the gasification thermal efficiency increased along with the CO2
fuel blends increased at a gasification temperature of 900 °C, due mixing ratio at high gasification temperatures. Jayaraman and
to the alkali content of the biomass, and especially the presence of Gokalp (2015) carried out char gasification to investigate the
potassium, which acts as a catalyst to aid in the process of char kinetic behaviors of gasification under a steam–CO2 environment
gasification. in the temperature range of 850–950 °C. They found that a higher
Compared to traditional approaches to the production of raw temperature reduced the time required for 50% char conversion.
biomass energy, the application of torrefied biomass is attracting Despite the potential advantages of using steam–CO2 mixtures
increasing attention in recent years, as it offers several advantages. as a gasifying agent, as detailed above, the process of co-
Torrefied biomass is produced by thermally pretreating the raw gasification under a steam–CO2 environment for a class of power
biomass. This process is known as torrefaction, which is a mild generation system has not yet been investigated. The present
pyrolysis process carried out in the temperature range of 200– study thus aims to design a combined heat and power (CHP)
300 °C under an inert or nitrogen atmosphere. Torrefaction system based on the steam co-gasification of biomass and coal
enhances the physical and chemical properties of raw biomass. with the addition of CO2. Particular emphasis is placed on the
Torrefied biomass has the following improved properties com- comparison of co-gasification performance between raw/torrefied
pared with the untreated material (Chen and Kuo, 2011; Sarvar- biomass and coal blends. Two important parameters of the steam-
amini et al., 2013; Thanapal et al., 2014; Kuo et al., 2014): (1) lower to-carbon ratio (S/C) and CO2 supply ratio (yCO2 ) are adjusted to
moisture content (hydrophobicity), (2) higher energy density, evaluate their influences on system performance. Finally, the
(3) greater ignitability, reactivity and grindability, (5) a lower optimum operating conditions are obtained by solving a series of
oxygen-to-carbon (O/C) ratio, and (6) lower costs of transportation constrained optimization algorithms
and storage. Torrefied biomass is thus seen as a more valuable and
economic fuel than raw biomass. In the recent literature Deng
et al. (2009) reported that a combination of torrefaction and co- 2. Process simulation
gasification is a promising process for the production of syngas.
Chen et al. (2011) gasified torrefied sawdust in a bench-scale Coal and two types of biomass, namely raw wood (RW) and
laminar entrained-flow gasifier, and found that the cold gas effi- torrefied wood (TW), are selected as the feedstock for gasification
ciency increased compared to that of raw sawdust, especially for and co-gasification in this study (Park et al., 2012). Their proper-
sawdust torrefied at 250 °C. Weiland et al. (2014) observed that ties, such as proximate analysis, elemental analysis, and higher
carbon conversion was improved by using torrefied wood residue heating values (HHV), are presented in Table 1. The simulation
as a feedstock in an entrained flow gasifier. Furthermore, and more model is established using a commercial heat and mass balance
recently, Dudyński et al. (2015) used torrefied woody biomass for analysis package, Aspen Plus V8.4. The following main assump-
industrial-scale gasification experiments, and found that syngas tions are made in this study for developing the process model:
with a higher calorific value was obtained by using torrefied pel- (1) the process is steady-state; (2) the feedstock is at normal
lets as a feedstock. conditions (i.e. 25 °C and 1 atm); (3) the solid and gaseous phases
These earlier studies show that torrefaction in association with are in a state of thermodynamic equilibrium; (4) the following
gasification is an effective and promising method to enhance the gaseous species are considered in the whole system: H2O, H2, O2,
performance of gasification. Although numerous works have N2, CO, CO2, CH4, H2S, COS, SO2,HCN, NO, NO2 and NH3; and
investigated the gasification characteristics of torrefied biomass, (5) char only contains carbon and ash, and tar formation is
little information is available on the co-utilization of coal and neglected (Kannan et al., 2013; Shen et al., 2008; Song et al., 2013).
torrefied biomass during a steam co-gasification process. On the In the simulation, the global thermodynamic property method
other hand, the integrated gasification combined cycle (IGCC) used in this model is the Peng-Robinson equation of state with the
P.-C. Kuo, W. Wu / Chemical Engineering Science 142 (2016) 201–214 203
Boston-Mathias alpha function (PR-BM). The fuels are defined as and ash. The product yield distributions in RYield are calculated by
an unconventional component, based on the experimental results a calculator block which is controlled by the FORTRAN statement
of elemental analysis and proximate analysis. Due to the non- in accordance with the component characteristics of the feedstock
conventional stream for the fuels, the HCOALGEN model, including (Table 1). The heat of the reaction from the decomposition is
a number of empirical correlations for heat of combustion, heat of simulated by a heat stream (Qdecomp).
formation, and heat capacity, is used in the simulation. The density For the gasification model, an RGibbs reactor is used to model
of nonconventional fuels is established by the DCOALIGT model reactions according to chemical equilibrium. In this block, the
(Ramzan et al., 2011). The simplified block diagram of the whole chemical and phase equilibrium calculations are carried out by
system is shown in Fig. 1, which consists of a gasification unit, gas minimizing the Gibbs free energy. The mathematical model of the
cooling unit, gas cleaning unit, gas burning unit, and power RGibbs reactor is described in a previous study (Kuo et al., 2014),
generation unit. and this reactor is operated at 900 °C (Howaniec and Smolinski,
2013; Jayaraman and Gokalp, 2015; Prabowo et al., 2014). The heat
2.1. Co-gasification system of the reaction from the endothermic gasification reactions is
simulated by a heat stream (Qgasifier).The detailed operating con-
Fig. 2a shows a schematic of the co-gasification process, which ditions of the co-gasification process are presented in Table 2, and
is composed of a number of blocks. The total mass flow rate of fuel the major chemical reactions that take place during the gasifica-
into the system is kept constant at 100 kg/h throughout the tion are listed below (Prabowo et al., 2014; Taba et al., 2012,, 2013):
simulations. When the “fuel” (stream 1) is fed into the system, the Water gas reaction
first stage is the drying of the fuel. An RStoic reactor is used to
C þ H2 O-CO þH2 ; ΔH0 ¼ þ 131:4kJmol 1 ð2Þ
simulate the drying process and the heat produced by the reaction
is simulated by a heat stream (Qdrying). The process of drying is Water gas shift reaction
simulated by the following chemical reaction (Chen et al., 2013):
CO þ H2 O2CO2 þ H2 ; ΔH0 ¼ 42kJmol 1 ð3Þ
Fuel-0:0555H2 O þ fueldry ð1Þ
Boudouard reaction
After fuel drying, a yield reactor is used to simulate the
decomposition of fuel. In the yield reactor, the unconventional C þ CO2 -2CO; ΔH0 ¼ þ172:6kJmol 1 ð4Þ
components of the fuel (stream 2) are decomposed into conven- Methanation reaction
tional constituents (stream 3), including N2, O2, H2, S, H2O, carbon
C þ 2H2 2CH4 ; ΔH0 ¼ 75kJmol 1 ð5Þ
Table 1
Proximate and elemental analyses of the feedstock used in the simulation (Park et CH4 þ H2 O2CO þ 3H2 ; ΔH0 ¼ 206kJmol 1 ð6Þ
al., 2012).
Regarding the gasifying mediums (stream 4), steam and CO2,
Feedstocks Raw wood Torrefied wood Coal are mixed and preheated by a heater (H1) before being fed into the
RGibbs reactor. Notably, a heater (H1) with a heat stream (Qgasifying
Proximate analysis (wt%)
Moisture 3.81 3.19 6.67 agents) is used to adjust the inlet temperature from 25 °C (stream 4)
Volatile matter (VM) 88.72 81.19 27.25 to 200 °C (stream 5). The outlet stream (stream 6) resulting from
Fixed carbon (FC) 7.42 15.51 54.5 the RGibbs reactor is divided into two streams, product gas
Ash 0.05 0.11 11.58
(stream 7) and char (stream 8) through an SSPLIT block. The
Elemental analysis (wt%)
C 46.73 52.22 74.12
product gas is cooled down by a cooler (C1), which reduces the
H 6.46 5.18 4.22 temperature to 150 °C (Emun et al., 2010). The steam and acid
N 0.41 0.55 1.91 gases produced from the co-gasification process are then removed
Oa 46.35 41.94 6.93 from the product gas in a separator block, where a heat stream
S 0 0 0.41
Higher heating value (MJ/kg) 18.51 20.56 26.82
(Qsep) is simulated to the energy demand of the separator. The
clean gas (stream 9) is then obtained and combusted with excess
a
By difference. air (stream 11) in order to provide complete combustion in the
Gasifying agents
Fuels (Steam/CO2)
(RW, TW, Coal)
Co-gasification Gas cooling and cleaning
Raw gas
Clean gas
Heat Recovery Steam
Power Generator (HRSG)
Gas Burning
and Rankine cycle
Flue gas
Fig. 2. Process flow chart of (a) the co-gasification system, and (b) power generation system.
burner to form flue gas (stream 12), which can be used in the pump in which it is pressurized from 1 to 240 atm, resulting in
power generation system. To validate the present model, simula- energy consumption (WPump). The high pressure feedwater
tions have been performed for gasification of rubber wood in a (stream 14) is then fed into shell side of the multi-stream heat
fixed bed gasifier operated at atmospheric pressure (1 atm) exchangers (feedwater regenerative heaters) and this water gets
(Mahishi and Goswami, 2007) and the gasification temperature is heated by the exhaust steam entering in the tube side, so that the
900 °C. The validation has been examined in a previous study (Kuo steam is heated to 250 °C (stream 17) and sent to the economizer.
et al., 2014), where the predicted results are in good agreement The steam (stream 17) is first heated by the outlet stream of the
with the experimental values. hot flue gas to the temperature of 550 °C after leaving the boiler
(stream 19). To achieve the supercritical state, the temperature of
2.2. Power generation system the steam is then raised from 550 to 600 °C through superheater 1,
and it subsequently feeds into a high pressure turbine (HPT)
The schematic process of power generation is shown in Fig. 2 (stream 20) to expand and produce electricity (WHPT). The pres-
(b) where the power generation system major consists of a steam sure of the steam exhausted from HPT is 49 atm (stream 21). The
generator and Rankine cycle (Chen and Wu, 2014). After burning Fsplitter (F1) is then specified as 0.7 and used to split the steam
the product gas from the co-gasification process, the high tem- stream; that is, a 0.195 kg/s of steam stream (stream 22) flows to
perature flue gas is obtained and sent to the heat recovery steam superheater 2 to reheat the temperature to 620 °C (stream 23),
generator (HRSG) and steam turbine (ST) process. A series of heat while a 0.0837 kg/s of steam stream (stream 28) is sent to the
exchangers is used, including a radiant water-wall evaporator, feedwater regenerative heaters to reheat the feedwater. Similarly,
radiant superheater, and economizer, in which steam is generated after reheating to 620 °C (stream 23) in superheater 2, the steam is
in conjunction with the heat transfer from hot product gas and also delivered into an intermediate-pressure turbine (IPT) and
then sent to three steam turbines, namely a high pressure (HP), exhausted to a low-pressure turbine (LPT) (stream 25) to produce
intermediate pressure (IP), and low pressure (LP) one, for power electricity (WIPT and WLPT). After removing the heat from the flue
generation. The detailed operating conditions of the steam cycle gas, the temperature of exhausted gas drops to 50 °C (stream 38)
are shown in Table 2. First of all, 0.279 kg/s of the feedwater (Sorgenfrei and Tsatsaronis, 2014), and the exhaust steam (stream
(stream 13) with a temperature of 45 °C goes through a water 37) is then cooled down to 45 °C at 0.1 atm as saturated water
P.-C. Kuo, W. Wu / Chemical Engineering Science 142 (2016) 201–214 205
Table 2 The ECE is defined as the ratio of energy output of the co-
Operating parameters of co-gasification for power generation systems. gasification system to the energy input, whereas NEE is the ratio
of net power generation to energy input (Mahishi and Goswami,
Parameter Value
2007; Speidel and Worner, 2015). The energy input is calculated as
Feedstock CH1.68O0.752N0.008 (raw wood) the sum of the energy content of the fuel, heat of reaction, and
CH1.04O0.486N0.006 (torrefied wood) energy requirement of the preheating gasifying agents and
CH0.683O0.070N0.022S0.002 (Coal)
separator. The energy output is the lower heating value (LHV, kJ/
Fuel flow rate (kg/h) 100
Blending ratio (wt%) 20–80 Nm3) of the product gas for the co-gasification system (Lv et al.,
Gasifier Temperature (°C) 900 2004; Kuo et al., 2014) or net power output (Ẇnet , kW) for the
Pressure (atm) 1 power generation system. These are defined as follows:
Burner Air flow rate (kg/h) 1000
Sensitivity analysis Steam to carbon ratio (S/C) 0.1–2 F productgas U GP U LHVproductgas
CO2 content in gasifying 0.01–2
ECEð%Þ ¼ ̇
100% ð10Þ
agents F fuel U LHVfuel þ Q H
Heat recovery steam generator Feedwater (kg/s) 0.279
(HRSG) and Rankine cycle HP steam turbine inlet 240 Q ̇H ¼ Q ḋ rying þ Q ̇decomp þ Q ̇gasifier þ Q ġ asifying agents þ Q ṡ ep ð11Þ
pressure (atm)
HP steam turbine inlet 600
temperature (°C) LHVproduct gas ¼ 30:0xCO þ 25:7xH2 þ 85:4xCH4 4:2 ð12Þ
Fsplitter (F1) 0.7
Steam mass flow rate (kg/s) 0.195 (stream Ẇnet
NEEð%Þ ¼ 100% ð13Þ
22) F fuel U LHVfuel þ Q ̇H
0.084 (stream
28)
Ẇnet ¼ ẆHPT þ ẆIPT þ ẆLPT ẆPump ð14Þ
IP steam turbine inlet 49
pressure (atm)
where F productgas and F fuel are the mass flow rates of the product
IP steam turbine inlet tem- 350
perature (°C)
gas and fuel (kg/s), respectively; GP is the volume of product gas
Fsplitter (F2) 0.9 from the gasification per unit weight of fuel (Nm3/kg-fuel); Q ̇H is
Steam mass flow rate (kg/s) 0.186 (stream the heat required for the co-gasification process (kW); x stands for
25) the mole fraction of gas species in the product gas (dry basis);
0.009 (stream
Ẇnet is the net power of the whole system (kW); ẆPump is the
32)
LP steam turbine inlet 5 energy requirement of the water pump (kW), and ẆHPT , ẆIPT , and
pressure (atm) ẆLPT are the energy outputs (kW) from individual steam turbines,
Fsplitter (F3) 0.9 corresponding to the high-pressure turbine, intermediate-
Steam mass flow rate (kg/s) 0.176 (stream
pressure turbine, and low-pressure turbine, respectively.
27)
0.009 (stream
35) 2.5. Exergy analysis
Condenser pressure (atm) 0.1
Ṗ Ṗ
where yc is the carbon content in the fed fuel, and yCO2 is defined where Exi and Exj are the exergy rates of the input and output
by the weight ratio of the CO2 contained in the total gasifying in out
streams, respectively. Ėxfuel is the input exergy rate of fuel (kW),
agents from both steam and CO2. That is, when yCO2 is equal to 0, it
means that steam is the only gasifying agent fed to the gasifier. Ėxgasifyingagents is the exergy rate of the gasifying agents (kW), Ėxheat
In addition, four biomass blending ratios (BR) of raw/torrefied is the exergy rate of heat required by the gasification system (kW),
biomass and the coal are considered for the co-gasification pro- Ėxproduct gas is the output exergy rate of the product gas (kW), Ė
xchar is the exergy rate of char (kW), Ėxw is the exergy rate of work
cess, and these are 20, 40, 60, and 80 wt%, which are expressed as
(kW), and Ėxloss is exergy loss rate from the system (kW).
F biomass Therefore, the total exergy of the material streams includes
BRðwt%Þ ¼ 100% ð9Þ
F biomass þ F coal physical exergy and chemical exergy, and these are defined in the
following equations:
2.4. Energy analysis
Ėxtotal ¼ Ėxph þ Ėxch ð18Þ
The energy conversion efficiency (ECE) and net energy effi- where Ėxtotal represents the total exergy of the material streams
ciency (NEE) are two important indexes with regard to the per- (kW), Ėxph is the physical exergy of the material streams (kW), and
formance of the system, and thus they are evaluated in this study. Ėxch is the chemical exergy of the material streams (kW).
206 P.-C. Kuo, W. Wu / Chemical Engineering Science 142 (2016) 201–214
Fig. 3. Distributions of (a) H2 flow rate, (b) CO flow rate, (c) CO2 flow rate in the product gas, and (d) char flow rate from steam gasification of three fuels.
In the foregoing equation, the Ėxph for each species in the For coal, the specific chemical exergy can be expressed by
product gas can be described by (Zhang et al., 2013)
̇
Ėxph ¼ ðh h0 Þ T 0 ðs s0 Þ ð19Þ Excoal ¼ Q L 1:0438 þ 0:0013H=C þ0:1083O=C þ 0:0549N=C
þ 6:710S O=C r 0:666 ð22Þ
where h and s are the specific enthalpy and entropy of the gas
species at a given state, while h0 and s0 are the specific enthalpy where Q L is the heating value of the coal (kJ/kg), and C, H, O, N, S
and entropy of the gas species at the environment state T 0 ¼ 25 °C are the mass fractions of carbon, hydrogen, oxygen, nitrogen, and
and P 0 ¼ 1 atm, respectively. sulfur, respectively.
The Ėxch for each species in the gas mixture can be evaluated as However, for biomass, the specific chemical exergy can be
follows: obtained by (Prins et al., 2003; Zhang et al., 2012)
̇ X n
Ėxbiomass ¼ βF biomass LHVbiomass ð23Þ
Exch ¼ ni Exch;i þ RT 0 ln P i ð20Þ
i
ni 1:044 þ 0:0160H=C 0:3493O=Cð1þ 0:0531H=CÞ þ 0:0493N=C
β¼ ðO=C r2Þ
1 0:4124O=C
where ni is the mole flow rate of species i in the product gas ð24Þ
(kmol/s), Exch;i is the standard chemical exergy of species i in the
where LHVbiomass is the heating value of the biomass (kJ/kg), and C,
product gas, and R is the universal gas constant (kJ kmol 1 K 1).
H, O, N are the mass fractions of carbon, hydrogen, oxygen, and
The exergy of heat streams is defined as follows (Kaska, 2014):
nitrogen, respectively.
X T0
As a result, the exergy efficiency (EE) of the product gas in the co-
Ėxheat ¼ 1 QH ð21Þ
T gasification system is defined by (Prins et al., 2003; Zhang et al., 2012)
Ėxproduct gas
where T is the operating temperature for the system, and Q H is the EEð%Þ ¼ 100% ð25Þ
Ėxfuel þ Ėxgasifying agents þ Ėxheat
heat requirement of the system (kW).
P.-C. Kuo, W. Wu / Chemical Engineering Science 142 (2016) 201–214 207
for all three fuels. The maximum LHV of the product gas should be optimization algorithms, as follows,
determined in order to find the maximum efficiency of the steam
F out
syngas
gasification process (Fig. 4b), which implies that the maximum max J i ¼ F out
syngas i ¼ ; i ¼ I; II; III ð27Þ
uij F in
syngas formation should be first optimized (Fig. 2). According to i
Δ F steam
0:1 r S=C ¼ r2 ð29Þ
yc F in
i
where F out
syngas j i represents the objective (Ji) of different fuels, I; II; III
are three kinds of fuel, corresponding to RW, TW, and coal, and
h iT
uij ¼ F steam ; F in
i represents the steady-state operating conditions.
j
To determine the optimal steady-state operating conditions, the
lower and upper bounds of uij , ai and bi , are given in Table 3. As a
result, the optimization of the maximum syngas formation of the
steam gasification process subject to constraint equations is
described by FORTRAN code and carried out in the Aspen Plus
environment based on the sequential quadratic programming
(SQP) method.
The optimal solutions are achieved through the specific opti-
mization algorithm and the optimal values of RW, TW, and coal are
obtained at S/C ratios of 0.4, 0.8, and 1.35, respectively. Notably, as
mentioned earlier, these locations with respect to the S/C ratio are
so-called carbon boundary points (CBPs), where no more carbon is
observed with a further increase in the S/C ratio (Fig. 2d).
Similarly, the maximum ECE and EE are obtained by solving the
following optimization algorithms
max J i ¼ ECEi ; i ¼ I; II; III ð30Þ
uij
max J i ¼ EEi ; i ¼ I; II; III ð31Þ
uij
subject to
aj r uij r bj j ¼ 1; 2 ð32Þ
Δ F steam
0:1 r S=C ¼ r2 ð33Þ
yc F in
i
Fig. 5. Distributions of (a) energy conversion efficiency, and (b) exergy efficiency
from the steam gasification of three fuels.
Table 3
Bounds of manipulated variables.
ui;j aj bj
ui;1 ¼ F steam kg=h 0 150
in
10 100
ui;2 ¼ yc F i kg=h
ui;3 ¼ F CO2 kg=h 0 10
uIV;1 ¼ F steam kg=h 0 150
uIV;2 ¼ yc F in 0 100
coal kg=h
in
uIV;3 ¼ yc F biomassl kg=h 0 100
uV;5 ¼ F steam kg=h 0 130
uV;6 ¼ F CO2 kg=h 0 20 Fig. 6. Profiles of syngas flow rate, energy conversion efficiency, and exergy effi-
ciency from the steam gasification of three fuels at the carbon boundary point.
P.-C. Kuo, W. Wu / Chemical Engineering Science 142 (2016) 201–214 209
Fig. 7. Distributions of the flow rates of H2, CO, and CO2 in the product gas from the
steam–CO2 gasification of (a) raw wood, and (b) torrefied wood at various CO2
supply ratios.
maximum syngas formations of RW, TW, and coal are 7.70, 9.33,
and 13.10 kmol/h (Fig. 3), respectively, revealing that the process
of syngas formation is enhanced by a factor of 21.17% when the TW
is gasified. Furthermore, both the ECE and EE can be improved by
up to 4.04% and 5.43%, respectively. It is thus verified that steam
gasification using TW to replace RW as a fuel can not only facilitate
syngas production, but also improve the energy and exergy
efficiencies.
Efficiency (%)
uij 86
11
max J i ¼ EEi ; i ¼ I; II ð35Þ
uij
84
10
subject to
aj r uij r bj j ¼ 1; 2; 3 ð36Þ 82
9
Δ F steam
0:1 rS=C ¼ r2 ð37Þ
yc F in
i 8 80
0 20 40 60 80 100
Δ F CO2 BR (%)
0:01 r yCO2 ¼ r 0:2 ð38Þ
F steam þ F CO2
Fig. 9. Distributions of the (a) syngas flow rate versus S/C ratio, and (b) optimal
h iT values of energy conversion efficiency and exergy efficiency from the steam co-
where uij ¼ F CO2 ; F steam ; F in
i represents the adjustable variables. gasification of blending torrefied wood with coal at various BRs.
j
Similarly, the upper and lower bounds of uij are shown in Table 3.
Therefore, the maximum values of ECE (Fig. 8b) and EE (Fig. 8c) values of efficiencies under the condition of various BRs, the fol-
from the steam–CO2 gasification of RW and TW are located at the lowing constrained optimization algorithms are solved by adjust-
same place of yCO2 ¼ 0:065, where their values are 83.35 and ing three operating variables (F in in
coal ; F biomass ; F steam ),
87.74% for ECE, while 77.07 and 82.60% for EE, respectively. It is
max J i ¼ ECEi ; i ¼ IV ð39Þ
thus verified that steam gasification with CO2 utilization further uij
promotes the system performance, especially for the case of TW,
revealing that 0.64% and 0.18% increase in ECE and EE are max J i ¼ EEi ; i ¼ IV ð40Þ
achieved, respectively. uij
subject to
3.3. Co-gasification characteristics and optimization
aj r uij r bj j ¼ 1; 2; 3 ð41Þ
From the above observations, it is evident that the gasification
Δ F steam
performance is effectively enhanced by using TW as a fuel in a 0:1 r S=C ¼ r2 ð42Þ
steam–CO2 environment. On account of the advantages of TW, the yc F in
i
of power output for different BRs at CBP are examined in Fig. 10.
Δ F steam
When coal (i.e. BR ¼0 wt%) and biomass (i.e. BR ¼100 wt%) are 0:1 r S=C ¼ r2 ð49Þ
used without blending in power generation system, the power yc F in
i
output for RW, TW, and coal are 278.70, 337.53, and 475.76 kW,
Δ F CO2
respectively. This suggests that using TW as an alternative fuel to 0:01 r yCO2 ¼ r 0:2 ð50Þ
F steam þ F CO2
RW can significantly increase the power output by a factor of
T
21.11%. For the cases of different BRs, the results indicate that the where uij ¼ F steam ; F CO2 j represents the adjustable variables. The
power output of TW blending is higher than that of RW blending, upper and lower bounds of uV;j are presented in Table 3. The
no matter which BR is examined. From the viewpoint both of optimal values of ECE and EE are 86.24 and 84.81, respectively,
power generation and GHG emissions, if the TW-based fuel at when the CO2 supply ratio is operated at 0.08, and these produce
BR ¼20 wt% is used in the co-gasification power generation system 1.04 and 0.34% increases in ECE and in EE, respectively. Notably,
then the power output is only improved by a small extent com- when comparing the increases in both of ECE and EE, the impact of
pared with RW-based fuel, and this BR causes more GHG emis- CO2 utilization on co-gasification of TW blended with coal is more
sions due to the 80 wt% coal contained in the fuel. However, once significant than those seen with gasification of TW alone (Fig. 8b).
the BR is 40 wt%, the power output from the TW-based fuel is
enhanced by a factor of 8.43%. As a consequence, the condition of
BR ¼40 wt% for the TW-based fuel is the recommended operating 4. Net system efficiency and CO2 emissions
conditions for the co-gasification power generation system.
The net system efficiency (NEE) and overall exergy efficiency
3.5. Co-gasification with CO2 utilization and optimization (OEE) of the whole system are two key indicators for evaluating
the performance of the whole system, and these are defined in
The above observations show that the blending of 40 wt% TW Eqs. (13) and (26), respectively. In addition to these two indicators,
with 60 wt% coal is a better feedstock for a CHP system. For this the specific CO2 emissions when the biomass is assumed to be CO2
reason, the performance of co-gasification with CO2 utilization and neutral are also evaluated. The specific CO2 emissions are
the TW-based fuel at BR ¼40 wt% is carried out, with the results expressed by
shown in Fig. 11. With CO2 utilization, the LHV of the product gas,
F out
CO2
ECE, and EE are also significantly improved. Most importantly, the ECO2 ¼ ð51Þ
optimal conditions of the CO2 supply ratio should be determined W net
in this context. Similarly, the specific optimization algorithm is where ECO2 is the specific CO2 emissions (kg/kW h), and F out
CO2 is the
performed using the two operating variables (F steam ; F CO2 ), and the mass flow rate of CO2 emitted to the environment (kg/h).
212 P.-C. Kuo, W. Wu / Chemical Engineering Science 142 (2016) 201–214
Therefore, according to the optimum operating conditions, as and 0.99%, the CO2 specific emissions are reduced significantly by
mentioned earlier, the results for the blending of 40 wt% TW with 38.23%, meaning that CO2 specific emissions can be effectively
60 wt% coal and 100 wt% coal are compared with each other, as suppressed. Summarizing the observations in Figs. 11 and 12, it is
shown in Fig. 12. Although the values of NEE and OEE of the CHP verified that CO2 addition could effectively improve energy effi-
system using coal blended with TW as a fuel fall by about 3.55% ciency for co-gasification plants. From the viewpoint of environ-
mental pollution and the greenhouse effect, reusing CO2 into the
production of useful fuels is an attractive process. Moreover, co-
gasification of biomass and coal is also able to reduce CO2 emis-
sions, and can also reduce NOx and SOx levels in flue gases. For
these reasons, this technology is worth investigating thoroughly.
Table 4
Optimization of co-gasification power generation system from blending of 40% TW
with 60% coal.
Fig. 13. Process with heat integration under optimal operating conditions: (a) co-gasification system, and (b) power generation system.
P.-C. Kuo, W. Wu / Chemical Engineering Science 142 (2016) 201–214 213
5. Conclusions Superscripts
This study designed a combined heat and power (CHP) system, 0 standard reference state
and examined the performance of gasification and co-gasification
under a steam–CO2 atmosphere using two types of biomass (RW Subscript
and TW). The main results of this work are as follows:
ch chemical
1. Based on the steam gasification of three fuels, the optimal ph physical
values of ECE and EE occur at the ratios S/C of 0.4, 0.8, and 1.35 i, j species i, j
corresponding to RW, TW, and coal, respectively, where these
points are exactly located at the CBP.
2. The optimal values of ECE and EE can be effectively improved by
CO2 utilization in steam gasification, especially for TW gasifi- Acknowledgments
cation. Under the optimal CO2 supply ratio of 0.065, increases of
0.64% and 0.18% of ECE and EE are achieved, respectively. The authors would like to thank the Ministry of Science and
3. 40 wt% TWþ60 wt% coal is the recommended fuel for the CHP
Technology, Taiwan, for its partial financial support of this
system. With regard to process optimization, the simulation
research under Grant MOST 103-2221-E-006-251.
shows that CO2 specific emissions at the optimal operating
conditions are reduced by 38.23%, compared to those found
with coal. Furthermore, based on the heat integration design for
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