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SIMULATION STUDY OF POULTRY SLUDGE GASIFICATION USING ASPEN PLUS

Conference Paper · September 2019

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22. Is Bilimi ve Tekni i Kongresi / 22nd Congress on Thermal Science and Technology
11-14 September/Eyl l 2019, KOCAEL

SIMULATION STUDY OF POULTRY SLUDGE GASIFICATION USING ASPEN PLUS

A. B. A. Ibrahim*, H. AL-Qadasi**, G. M. OZKAN**, H. AKILLI**
*University of Blue Nile, Faculty of Engineering, Mechanical Engineering Department
Blue Nile State, SUDAN, saadalla_85@yahoo.com
** Cukurova University, Faculty of Engineering, Micanical Engineering Department
01330 Saricam, Adana

Abstarct: Recently, the use of gasification technique to convert biomass into clean fuel gas (syngas) is a promising
technology. The quality of produced syngas essentially depends on the biomass source, operation parameters, and
gasifier reactor design. However, the successful design of the gasifier reactor is not an easy task. Moreover, the
efficient methods to predict the gasification performance are yet not available due to less understanding of the
thermodynamic process. In this study, a steady state model for poultry sludge (PS) gasification is developed using
ASPEN Plus process simulator software to predict the composition of produced syngas. Since ASPEN Plus simulator
does not contain a built-in gasifier reactor model, a combination of various reactors is used to simulate the gasification
processes. These processes are divided out into two stages. In the first stage, biomass is decomposed into its element
by specifying yield distribution. By using Gibbs free energy minimization approach, the gasification reactions are
modeled. The current model is validated with the previously published work. Therefore, the varied wide ranges of
operation parameters, which include reaction temperature, reaction pressure and equivalence ratio, are performed to
assess their influences on the syngas composition. Furthermore, the effect of PS moisture content on the heating value
of syngas was also explored. The increase in reaction temperature (673-1673K) is enhanced the production of CO and
maximum H2. Increasing reaction pressure adversely affects the generation of H 2 and CO. The higher mole fraction of
H2 and CO can be obtained at lower equivalence ratio. The heating value of syngas sharply decreases with the increase
in the PS moisture content. From the simulation results, ASPEN Plus simulator software is presented a high capability
to be used as a predictive tool for optimization of the gasifier performance.
Keyword: Poultry sludge, Gasification, Syngas, Operation paramter, ASPEN Plus.

INTORODUCTION
Gasification is a thermochemical conversion method
converting biomass into fuel gas which termed as a
syngas (Naik et al., 2010; Susastriawan et al., 2017).
Syngas is mainly a mixture of combustible gases such as
H2, CO and CH4, and non-combustible gases such as CO2
and N2 (Bhoi et al., 2018; Ibrahim and Akilli, 2019). The
gasification process includes drying, pyrolysis,
combustion, and reduction process as elaborated by
Diyoke et al. (2018). Typically, the quality of syngas is
affected by some essential parameters such as biomass
characterization, process operation parameters, and the
gasifier reactor design (Susastriawan et al., 2017). The
biomass characterizations depend on the biomass source.
The significant biomass characterizations on gasification
process include size, density, ultimate analysis (carbon
(C), hydrogen (H), nitrogen (N) and sulfur (S)) and
proximate analysis (volatile matter (VM), fixed carbon
(FC) and ash) (Han et al., 2017; Kumar et al., 2017). The
operation parameters in biomass gasification are reaction
temperature, reaction pressure, equivalence ratio and
moisture content.
Kirsanovs et al. (2017) investigated the effect of wood
chips moisture content on the syngas production
efficiency. They found lower moisture content was
favorable for syngas production. Moreover, the high
moisture content decreases the calorific value of syngas
as reviewed by Susastriawan et al. (2017). At high
moisture content, McKendry (2002) mentioned the
reduction in the syngas calorific value due to incomplete
pyrolysis process. The effect of reaction temperature
through the gasification process was explored by Liu et
al. (2012). They stated that high temperature promoted
tar cracking, then improved the endothermic gasification
reaction rate and enhanced the yield of syngas
production. Wang et al. (2015) studied the effect of
reaction temperature on the gasification of two
commercial biomass pellets (pinewood sawdust and
cotton stalk). They observed that the percentage of CO
and H2 in syngas increases with increasing reaction
temperature thus increases the heating value of syngas. In
contrast, the increase in the reaction pressure decreases
the percentage of CO and H2 in syngas (Higman and Van
der Burgt, 2008). Kaupp and Gross (1981) stated the
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effective gasification process occurs when equivalence Table 1. The preliminary characterization of poultry
ratio (ER) within the range of 0.2 to 0.4. Beyond 0.4, the sludge
gasification process shifts from pyrolysis domain to Initial Moisture content (%) 68.3
combustion domain (Olgun et al., 2011). In general, the High Heating Value (MJ/Kg) 27.2
results of the previous studies have a similar trend.
However, the optimum operating parameters for biomass Proximate Analysis (wt.% db.)
gasification are affected by the biomass characterization Volatile matter 64.7
and gasifier design. Fixed carbon 21.8
ash 13.5
The design of gasifier reactor dimensions and capacity of
the syngas production assign based on the specific Ultimate analysis (%)
biomass characterizations. Moreover, the C 56.1
characterizations of one type of biomass are different H 8.0
from others. From this, biomass is recognized as the
most vital key in the gasifier reactor design. Due to the N 5.3
high expenses of gasifier reactor design, many biomass S 0.7
gasification models were carried out to study the O 16.4
feasibility of biomass gasification and to predict the
amount and composition of syngas production (Ramzan
et al., 2011; Diyoke et al., 2018; Gambarotta et al.,
2018; Prabhakar et al., 2018).

The poultry sludge (PS) is a major environmental

problem that generates from chicken processing sector
due to its hazard material content. In Turkey, This sector
is rapidly growing not only to meet the national demand
but also to support the government plan to become the
first exporter for Hala chicken in the Middle East and
European region. The conversion of PS into the usable
form of energy reduces the dependence on fossil fuel and
alternative solution to its disposal problems. Due to lack
of information on the feasibility of PS gasification
process, the gasification model of PS is developed using Figure 1. Compression of moisture content of poultry sludge
commercial simulation software ASPEN Plus in the with other solid fuel sources
current research. The steady state model is used to
describe the gasification process of PS. The effects of the
operation parameters which include reaction temperature,
reaction pressure, and ER on the syngas composition are
investigated. Furthermore, the influence of PS moisture
content on the high heating value of produced syngas is
successfully explored.

PRELIMINARY CHARACTERIZATION

PS sample was collected from poultry processing plant

located southern regions of Turkey. The sample dried by
using a convection oven to determine the initial moisture
content. Then, the dried sample was labeled and stored in
an air-tied plastic bag for further analysis. The essential
fuel characterizations of PS, the ultimate analysis,
proximate analysis, and high heating value (HHV)
measurement, were carried out.
Table 1 represents the PS characterization results of the
mentioned measurements. The results showed that PS
has a higher HHV than other wastewater sludge sources
and low-rank coal. Furthermore, PS revealed an
acceptable initial moisture content in comparison to other
wastewater sludge and low-rank coal, as shown in Fig. 1
and 2.
Figure 2. Compression of moisture content of poultry sludge
with other solid fuel sources
ASPEN PLUS MODEL DEVELOPMENT
ASPEN Plus software is used to develop a kinetic free
equilibrium for the gasification process. However, as the
gasifier model does not exist in the ASPEN Plus process
simulator, the gasification process in this study was
modeled in two stages. In the first stage, the feedstock
decomposed into volatile component and char in the
second stage. The FORTRAN statement was employed
in the calculator block to specify the yield distribution in
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this stage. Finally, the gasification reaction was modeled separated from the syngas by using Sep block model
by minimizing Gibbs free energy. based on the split fractions.

Assumption Table 2.. Description of ASPEN Plus unit operation models

ASPEN Block ID Description
The basic assumptions in the model are: Plus ID
1. Steady state kinetic free model Yield reactor-converts non-
2. Isothermal system conventional biomass into
3. All sulfur goes to H2S RYield DECOMP
conventional components by
4. Only NH3 forms, no oxides of nitrogen are using FORTRAN statement.
produced. Gibbas free energy reactor-
5. Tars and other products are assumed as non- handles three phase
equilibrium products to reduce hydrodynamics RGibbs GASIF equilibrium and calculates
complexity. syngas composition by
minimizing Gibbs free energy.
Physical property method Separates gases from ash by
Sep SEPARAT
specifying split fractions.
Among the equation of states that available in ASPEN
Plus, Peng-Robinson equation with Boston-Mathais alpha
function (PR-BA) used in the current study. This method
improves the correlation of the pure component vapor
pressure when the temperature is very high because the
alpha parameter in this package is a temperature
dependent variable. Moreover, the enthalpy and density
model for non-conventional components (biomass and
ash) were specified as HCOALGEN and DCOALIGT
respectively.

Model Description

PS is defined as a non-conventional component in

ASPEN Plus and specified by using ultimate and
proximate analysis, as shown in Table 1. In the model
simulation, four block models used to simulate the
gasification process, as mentioned in Table 1. Moreover,
Fig. 3 and presents the typically PS gasification processes
and calculation procedures used in ASPEN Plus.

The RGibbs block model is used to simulate the

gasification process of PS. This block models chemical
equilibrium by minimizing Gibbs free energy and can Figure 3. ASPEN Plus Simulation Calculation procedure
handle three-phase chemical equilibrium. However, the
equilibrium calculation cannot be done because PS is
defined as a non-conventional component. Concerning
this challenge, it is necessary to feed PS into the
simulation based on it is elements composition (C, H, N,
S, and O). For this purpose, the RYield block model is
employed. In this case, it is assumed that the volatile
content obtained from the proximate analysis of PS is
equal to the total yield of volatiles. Moreover, the
FORTRAN statement is connected to RYield block
model to calculate the yield distribution of PS into its
components.

The reaction temperature related to PS decomposition is

modeled in RGibbs block model. This block calculates Figure 4. Typically ASPEN Plus Simulation procedure for
the syngas composition by minimizing Gibbs free energy poultry sludge gasification
and assumes complete chemical equilibrium. The air
stream is attached to RGibbs block model where the
chemical equilibrium calculates. Finally, the ash is Model Validation
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The developed model validated by using the experimental

result of municipal waste material (MSW) gasification
published by (Ramzan et al., 2011). Table 3 showed that
the simulation results are in good agreement with the
experimental result for MSW. In this simulation, the
results showed better agreement with the syngas
composition of other authors, yet it still needs to be
validated with experimental data in the future.

Table 3.. Experimental result vs model prediction of MSW

Syngas [mole %] Experiment Model diff Figure 5. The effect of reaction temperature on the syngas
N2 67.34 68.67 1.33 mole fraction generated from poultry sludge
O2 1.2 1.09 -0.11
CO 14.89 14.74 -0.15
CO2 8.4 7.86 -0.54
H2 4.58 5.19 -0.61
CH4 1.54 0.39 -1.15

RESULTS AND DISCUSSION

In the developed model for PS gasification, the sensitivity

analysis is performed to assess the influence of the
reaction temperature, reaction pressure and equivalence
ratio (ER) on the syngas composition. Furthermore, the
effect of moisture content on syngas high heating value is
also investigated. Figure 6. The effect of reaction pressure on the syngas mole
fraction generated from poultry sludge
Reaction temperature

In this study, the reaction temperature varied from 673 to

1673 K. Fig. 5 presents the effect of reaction temperature

of gasification increase with the increase in the reaction

temperature. Ramzan et al. (2011) reported that, at low
temperature, the carbon present in biomass is not gasified
completely. In another hand, at the high reaction
temperature, carbon converts to CO according to
Boudourad reaction. Furthermore, CH4 presented in
syngas, at low temperature, can convert into H2 by
reversing the methanation reaction. In particular, H2 and
CO production sharply increase at a temperature above Figure 7. The effect of equivalence ratio on the syngas mole
fraction generated from poultry sludge
773 K. From these results, it can be concluded that the
increase in the gasification temperature favors CO and H2
Equivalence ratio (ER)
production from PS.
In this study, the equivalence ratio is defined as the ratio
Reaction pressure
of the amount of actual air supplied in the gasifier reactor
to the stoichiometric amount of air. In general, the excess
The sensitivity analysis of the reaction pressure inside the
ER is necessary for converting the carbon presented in
reactor was carried out to explore its effect on the syngas
PS, but the increase in the ER declined the syngas
composition. The reaction pressure varied from 0 to 40
production. This result because the oxygen in the excess
bar. The mole fraction of CO and H2 in the syngas
air completely oxidizes the PS. The CO and H2 mole
decreased rapidly with a slight change in CH4 at reaction
fraction in the syngas were slightly changed when the ER
pressure above 5 bar, as shown in Fig. 6. This result
increased from 0.2 to 0.5 due to increases in the
agrees with the result obtained by Higman and Van der
conversion rate of PS. Beyond 0.5, the CO and H 2 were
Burgt (2008). They concluded that the yield of CO and
steadily decreased while CO2 increased due to complete
H2 decreases with the increase in reaction pressure,
combustion of PS.
whereas CO2 increases.
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Moisture content
The moisture content plays an important role in
gasification performance. In this study, the moisture
content varied from 10 to 40%. Fig. 8 shows the effect of
moisture content on the high heating value of syngas
generated from PS. The increase in the moisture content
strongly decreased the high heating value. These result
because a part of PS heating value is used to evaporate
the moisture content.
Figure 8. The effect of moisture content on the high heating
value of syngas generated from poultry sludge
CONCLUSION
In this study, a steady state equilibrium model for PS
gasifier was successfully developed using the built-in
block models of ASPEN plus simulator. This model is
capable of predicting the gasification performance under
different operating parameters. The predicted results are
in agreement with previous studies values. High reaction
temperature enhanced the gasification efficiency via
increases the CO and H2 production in the syngas. In
contrast, the increase in the reaction pressure decreases
the gasification conversion efficiency. The conversion of
carbon presented in PS through the gasification process is
mainly controlled by the ER. The increase of moisture
content in PS decreases the HHV of syngas. In the
future, further study in the gasification process using
comprehensive models is recommended. Finally, validate
these models with the experimental results.
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oxygen-enriched air in a pilot scale two-stage gasifier.

Fuel 150, 386-393.