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Gasifier Design

Gasifier Design

What are the


components
of a gasifier?
Design of gasifier
• Process Design
• Type and yield of product
• Operating conditions
• Basic size of the reactor
• Hard ware design
• Structural and mechanical components

Air, steam, oxygen

Biomass Gasification Gas


Product gas
cleanup

Ash
Design of Gasifiers…

Design of a gasification plant includes the


gasifier reactor and its auxiliary or support
equipment ranging:
• Gasifier reactor
• Biomass-handling system
• Biomass-feeding system
• Gas cleanup system
• Ash or solid residue-removal
system
Design of Gasifiers (cont.)

Design of a gasifier reactor


may be divided into three
major phases

Phase 1. Process design


and preliminary sizing =>
type & yield of product, Phase 2. Optimization of Phase 3. Detailed
operating conditions and design mechanical design
the basic sizes of the
reactor will be determined
Design of Gasifiers (cont.)

At the end of process design, we will be able to


determine:
• Geometry including reactor configuration,
cross-section area, and height
• Operating parameters like reactor
temperature; preheat temperature of the steam,
air, or oxygen; and amount (i.e., steam/biomass
ratio) and relative proportion of the gasifying
medium (i.e., steam/oxygen ratio)
• Performance parameters like carbon
conversion and cold-gas efficiency
Design of Gasifiers (cont.)

Design Specification (Design Capacity)


The first point in the gasifier design is to
identify the application and the size/capacity
of the gasifier in term of the product
requirement and the fuel to be gasified,
That include
✓ Specification of the fuel
✓ Gasification medium
✓ Product gas
Design of Gasifiers (cont.)
Design Specification (cont.)
Specification of the Gasification
Product gas
fuel medium

proximate and Steam (HV in the


ultimate range of 10- Desired gas composition
analysis 18MJ/Nm3)

Oxygen (HV in the


operating
range of 12- Desired heating value
temperatures
28MJ/Nm3)
Air (HV in the
Desired production rate
ash properties range of 4-
(Nm3/s or MWth produced)
7MJ/Nm3)

Yield of the product gas per


unit fuel consumed

Required power output of the


gasifier, Q
Design of Gasifiers (cont.)

Mass Balance
1. Calculation of the rate of product gas
Product gas flow rate
Where
• Vg (Nm3/s), volume flow rate of the product gas
• Q (MWth), gasifier’s required power output,
• LHVg (MJ/Nm3),
• Desired lower heating value can be found/calculated
from
o the composition
o published data or similar plants
Design of Gasifiers (cont.)

Mass Balance (cont.)


2. Calculation of the fuel feed rate or biomass feed rate, Mf
fuel feed rate
Where
• LHVbm, LHV of the biomass related with HHV as

Hdaf is the hydrogen mass fraction in the fuel, Mdaf is the moisture mass
fraction, and HHVdaf is the HHV in kJ/kg on a moisture-ash-free basis

HHVd, is typically in the range 18 to 21 MJ/kg, calculated from the ultimate


analysis for the biomass using the following equation

(in mass fraction)


• ɳgef, gasifier efficiency
Design of Gasifiers (cont.)

3. Calculation of the Flow Rate of Gasifying Medium


•Three types of gasifying mediums: Air, Oxygen and Steam.
 Product Yield and composition greatly influenced by these
medium
Air 𝑀𝑎 = 𝑚𝑡ℎ𝐸𝑅 , 𝑀𝑓𝑎 = 𝑚𝑡ℎ𝐸𝑅𝑀𝑓
Where:
– mth, theoretical air requirement
– Ma, amount of air required for gasification of unit mass
– Mf, fuel feed rate
– Mfa, air requirement of the gasifier
• ER, is the (ratio of the actual air/stoichiometric air )
• (For biomass gasification 0.2≤ER ≤0.3)
Design of Gasifiers (cont.)

Mass Balance (cont.)


3. Calculate the Flow Rate of Gasifiying Medium
Design of Gasifiers (cont.)
3. Calculation of the Flow Rate of Gasifying Medium
Oxygen
• Oxygen is used primarily to provide the thermal
energy needed for the endothermic gasification
𝑘𝐽
reactions. 𝐶 + 0.5𝑂2 → 𝐶𝑜 − 111
𝑚𝑜𝑙
𝑘𝐽
𝐶 + 𝑂2 → 𝐶𝑂2 − 394
𝑚𝑜𝑙
• The first reaction will be the more likely that will be
held for the oxygen deficient environment
Oxygen/carbon =1.33
Design of Gasifiers (cont.)
3. Calculation of the Flow Rate of Gasifying Medium
Steam
• Superheated stem is used either alone, with air, or
with oxygen
• Contributes to the generation of hydrogen
C+H2O→CO+H2
• The quantity of steam can be determined from the
steam to carbon molar ratio (S/C)kg steam/kg fuel
a value in the range of 2.0 to 2.5 can give a reasonable
starting value.
Example
A moving-bed gasifier 4 m in diameter operates at 25 bars of pressure and consumes
750 kg/min (dry-ash–free basis) of bituminous coal, 1930 kg/min of steam, and 280
Nm3/min of oxygen to produce a product gas that contains 1000 Nm3/min of syngas
(a mixture of H2 and CO). The mean gasifier temperature is 1000 °C. The volumetric
composition of the product gas is: CO2–32%, H2S–0.4%, CO–15.2%, H2–42.3%, CH4–
8.6%, C2H4–0.8% & N2–0.7%
•The ultimate analysis of the coal on a moisture-ash-free basis is: C–77.3%, H–5.9%,
S–4.3%, N–1.4% & O–11.1%
•Find
✓ The S/C molar ratio
✓ The O/C molar ratio
✓ The ER
✓ The hearth load in energy produced per unit of grate area and space velocity
•The heating values of the product gas constituents may be taken from reference
books
Cont…
Given

Required
• The S/C molar ratio
• The O/C molar ratio
• The ER
• The hearth load in energy produced per unit of grate area and space
velocity
Cont…
• The coal is given in mass percent so we can calculate their amount in mass and number of
mole using the relations (mass %= individual mass/total mass and n=m/M respectively)

m n(Kmol/mi
(kg/min) n) In a similar way the mole of steam and oxygen is
C 579.75 48.3125 calculated. For oxygen at standard condtion the
H 44.25 22.125
S 32.25 1.0078125
volume of a gas is 22.4Nm3/kmol is taken so
N 10.5 0.375 nsteam=1930/18=107.22kmol/min and oxygen is
O 83.25 2.6015625 280/22.4=12.5kmol/min
S/C 2.22 O2
O/C 0.26 require
d

For calculating the equivalence ratio we need to n(kmol. m(kg/


m n min) min)
calculate the theroteical oxygen required to burn
the fuel i.e C, H and S. C 580 48.3125 48.3125 1546

C+O2->CO2, S+O2->SO2 and H2+0.5O2->H2O, H 44.3 22.125 11.0625 354

after this subtract the oxygen content of the fule S 32.3 1.0078125 1.008 32.25

ER=Actual/Theoretical O 83.3 2.6015625


Total O2 required
83.25
1849
=400/1849=0.216 O2 supplied =12.5*32 400
Cont..
syngas
(CO+H2) 1000 Nm3/min
It is given that the operating
XCO+XH2 57.5 % pressure and Temperature is 25
XCO+XH2= v(CO+H2)/Vtotal gas
Vtotal= 1739.5Nm3/min
bar and 1000oC(1273.15K)
respectively
𝑃1𝑉1 𝑃2𝑉2
= 𝑇2
𝑇1
V2=(1/25)(1273.15/273.15)(1739.5)=3
24.31m3/min HHV
Product gas (MJ/Nm3) HHV(MJ/Nm
Area =𝜋𝑟2 = 4𝜋𝑚2 composition (Vol%) Indvi 3)
Space velocity CO2 32 _

=V2/A=324.31/4𝝅=0.43m/s H2S
CO
0.4 _
15.2 12.63 1.91976
Hearth load =Energy produced /area H2 42.3 12.74 5.38902
Energy from the product gas= the sum of CH4 8.6 39.82 3.42452
the heating value of each gas i.e C2H4 0.8 63.41 0.50728
N2 0.7 _
sum 11.24058
Design of Gasifiers (cont.)

Energy Balance
• Gasification
reaction=>endothermic=>external heat
supply
• The amount of external heat supplied to
the gasifier depends on the heat
requirement of the endothermic reactions
as well as on the gasification temperature
Design of Gasifiers (cont.)
Design of Gasifiers (cont.)

• Energy input: Enthalpy of (biomass + steam +


oxygen) at reference temperature + heating value of
biomass + external heat
• Energy output: Enthalpy of product gas at gasifier
temperature + heating value of product gas + heat in
unconverted char + heat loss from the reactor
• If A is the amount of air needed and W is the total
steam needed to gasify F kg of fuel to produce 1Nm3
of product gas, we can write the energy balance of
the gasifier taking 0 °C as the reference
Design of Gasifiers (cont.)

Where
H0 and Hg =enthalpies of steam at the reference T and the gasifier exit T;
Ci and Vi are the volumetric specific heat and the volume of the gas species, i,
at T Tg leaving the gasifier;
(1 − Xg)W = the net amount of steam remaining in the product gas of the
gasification
reaction;
Pc =the amount of char produced; and qc = the heating value of the char.
Qloss =the total heat loss corresponding to 1 Nm3 of gas generation.
Qext kJ/Nm3 = external heat addition
Qproduct = the amount of energy in the product gas, and
Qg=gsification is the net heat of reaction.
Design of Gasifiers (cont.)

Energy Balance (cont.)


Gasifier Gasification Temperature
(oC)
Entrained-flow 1400-1700

Fluidized Bed 700-900

Cross-draft 1250-1500
Down-draft Up to 1000
Up-draft Up to 900
Design of Gasifiers (cont.)

Energy Balance (cont.)

Heat of Reaction
• The heat gained or lost in a chemical reaction is called
heat of reaction
• Heat of reaction = [the sum of all heats of formation of
all products] - [the sum of all heats of formation of all
reactants]
• To calculate it for gasification, we consider an overall
gasification reaction where 1 mol of biomass (CaHbOc)
is gasified in α moles of steam and β moles of oxygen
• The overall equation is
Design of Gasifiers (cont.)
• The heat of formation @ reference
temperature can be found from tables
• If the temperature is different from
reference :

Q gasification = ΔH(T) kJ /mol


Example

Find the heat of reaction for the


following reaction at 1000K
Cont…
Product Gas Prediction
• A typical gasifier design starts with a desired composition
of the product gas.
• Equilibrium and other calculations are carried out to
check how closely that targeted composition is made
through a choice of design parameters.
• Product gas composition estimation for combustion=>
relatively straight forward and can be determined from
stoichiometric relation
• Product gas composition estimation for gasification =>
not straight for ward and needs a careful estimation.
These reactions rarely reach equilibrium and hence
equilibrium calculation gives a rough estimate => for start
up of the design it is fair enough until detailed kinetic
modeling is carried out in the design optimization stage.
Product Gas Prediction (Co…)
Equilibrium Approach
There are two types of equilibrium model.
1. based on equilibrium constants (stoichiometric
model)
The specific chemical reactions used for the calculations
have to be defined
2. Based on minimization of the Gibbs free energy
(nonstoichiometric model).
• It is based on the premise that at an equilibrium stage the
total Gibbs free energy has to be minimized.
Design of gasifier reactor
Step 1: Process design
– Fuel feed rate
– Gasification medium
– Gasification temperature
Step 2: Gasifier type and configuration
– How can we choose the gasifier type?
– Geometric design=> the basic sizes will be
determined
Moving-Bed Gasifiers
• The main design parameters for a moving-
bed gasifier are: specific grate gasification rate, hearth
load, and space velocity
𝑘𝑔 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑓𝑢𝑒𝑙 𝑔𝑎𝑠𝑖𝑓𝑖𝑒𝑑
ℎ𝑒𝑎𝑟𝑡ℎ 𝑙𝑜𝑎𝑑( )=
𝑠𝑚2 ℎ𝑒𝑎𝑟𝑡ℎ 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎

𝑀𝑊 𝑒𝑛𝑒𝑟𝑔𝑦 𝑡ℎ𝑟𝑜𝑢𝑔ℎ𝑝𝑢𝑡 𝑖𝑛 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑔𝑎𝑠


ℎ𝑒𝑎𝑟𝑡ℎ 𝑙𝑜𝑎𝑑( )=
𝑚2 ℎ𝑒𝑎𝑟𝑡ℎ 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎

𝑁𝑚3 𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑔𝑎𝑠 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑟𝑎𝑡𝑒


ℎ𝑒𝑎𝑟𝑡𝑙𝑜𝑎𝑑 =
𝑠𝑚2 ℎ𝑒𝑎𝑟𝑡ℎ 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎
Moving-Bed Gasifiers(co….)
Updraft Gasifier
• The simplest and most common type for biomass gasification
• When the feed of air/oxygen increases the maximum
temperature will be obtained
• The amount of oxygen feed for the combustion reaction is
carefully controlled such that the temperature of the
combustion zone does not reach the slagging temperature of
the ash, causing operational problems.
• The gasification temperature may be controlled by mixing
steam and/or flue gas with the gasification medium.
• The hearth load
– For biomass 2.8 MW/m2 or 150 kg/m2/h for biomass
– For coal (oxygen based) >10MW/m2
Moving-Bed Gasifiers(co….)
updraft gasifier….
• The height of the moving bed is
generally greater than its diameter.
• Usually, the height-to-diameter ratio is
more than 3 : 1
• If the diameter of a moving bed is too
large, there may be a material flow
problem, so it should be limited to 3 to 4
m in diameter
Moving-Bed Gasifiers(co….)
Downdraft Gasifier
• The cross-sectional area of a downdraft gasifier
may be non-uniform; it is narrowest at the
throat.

Throated type downdraft


gasifier
Moving Bed…
• The hearth load is, therefore, based on the cross-sectional
area of the throat for a throated gasifier, and for a
throatless or stratified downdraft gasifier, it is based on
the gasifier cross sectional area.
• The total nozzle area is typically 7 to 14% of the throat
area.
• The number of nozzles should be an odd number so that the
jet from one nozzle does not hit a jet from the opposite side,
leaving a dead space in between.
• To ensure adequate penetration of nozzle air into the hearth,
the diameter of a downdraft gasifier is generally limited to
1.5 m => limits the size and capacity of the gasifier
Fluidized-Bed Gasifiers
Cross-Sectional Area

Ab: the inside cross-sectional area of the fluidized-


bed gasifier,
Vg = volumetric flow rate of the product gas flow
Ug= superficial gas or fluidization velocity through it,
at the operating temperature and pressure

Where
– Mfa= mass of gasification medium required for both
gasification and fluidization
– ρg is the density of the medium at the gasifier’s operating
temperature and pressure.
36
Fluidized-Bed Gasifiers(con…)
Fluidization Velocity
• The range of fluidizing velocity, U, in a bubbling bed
depends on the mean particle size of the bed materials.
• The range should be within the minimum fluidization
and terminal velocities of the mean bed particles.
• The particle size may be within group B or group D of
Geladart’s powder classification
• If the gasifier reactor is a circulating fluidized-bed type,
the fluidization velocity in its riser must be within the
limits of fast fluidization, which favors groups A or
group B particles.
• Typical fluidization velocity for particle size in the range
150 to 350 microns is 3.5 to 5.0 m/s in a CFB.
Fluidized-Bed Gasifiers(con…)
Gasifier Height
• To determine the hight of fluidized bed gas and
solid residence time are used instead of heat
transfer consideration (as gasification is
endothermic reaction)
• The total height of the gasifier is made up of
the height of the fluidized bed and that of the
freeboard above it:
• Total gasifier height = bubbling bed height
(depth) + freeboard height
Fluidized-Bed Gasifiers(con…)
Fluidized-Bed Height
The depth of bubbling bed fluidized bed as the deeper bed
allows long gas residence time but the depth should not be so
great compared to its diameter as to cause slagging
No simple means to select the bed height but it depends on
economics.
A higher bed height means a higher pressure drop and also a
taller reactor. It also should provide a longer residence time for
better carbon conversion.
The extent to which oxygen or steam is converted into fuel gases
depends on the gas exchange rate between the bubble and
emulsion phases as well as on the char gasification reaction rate
in the emulsion phase
Best computed through the kinetic model of the gasifier or
alternatively based on residence time approach
Fluidized-Bed Gasifiers(con…)
Residence Time Design Approach
• Bubbling fluidized bed should be deep to give the
time required to complete the gasification reaction
• The residence time approach is based on the
assumption that the conversion of char into gases
is the slowest of all gasifier processes, so the reactor
should provide adequate residence time for the char
to complete its conversion to the desired level.
• Given the following assumption:
– The reactivity factor fo (which lies between 0 ≤fo≤1).
– The solid is in a perfectly mixed condition (i.e.,
continuous stirred-tank reactor).
Fluidized-Bed Gasifiers(con…)
• Then, the volume of the fluidized bed, V, is
calculated using the equation

• Where
– Wout=char moving out; kg/s = (1-X) Win;
– X=fraction of the char in the converted feed;
– ρb= bed density, and
– θ is the residence time of the char in the bed, or
reaction time (s).
Fluidized-Bed Gasifiers(con…)
• The residence time approach assumes that the
water–gas reaction, (C + H2O → CO + H2) is the
main gasification reaction, where the char is
consumed primarily by the steam gasification
reaction for nth-order kinetics:

where m = initial mass of the biomass


C = the total amount of carbon gasified in
time, t.
Fluidized-Bed Gasifiers(con…)
• Experiments can be carried out taking a
known weight of the biomass and
measuring the change in carbon conversion
at different time intervals for a given
temperature, steam flow, and pressure.

The y-intercept will


give the value of k,
and the slope will give
the value of n.
Fluidized-Bed Gasifiers(con…)
We can express K as
k=koexp(-Ea/RT)
Or in logarithm form we can express
Lnk=lnko-Ea/RT
This shows that if we plot a graph between lnk and 1/T, the y-
intercept will give the value of k0 and the slope will give the
value of (-E/R).
The reaction rate for the steam gasification of biomass is given
by

This gives the generalized reaction rate that shows the


dependence of the gasification rate on temperature, mass of
carbon or char, and concentration of steam/air/oxygen.
Fluidized-Bed Gasifiers(con…)
• From a knowledge of the reaction rate, the
residence time, θ, can be calculated as:

• where C0= the initial carbon in the biomass


particle, kg; X = the required carbon conversion;
and r = the steam gasification reaction rate
(kg/s).
Fluidized-Bed Gasifiers(con…)
• From the required solid residence time, θ, then, the bed
volume, Vbed, is

• where F[C] is the char feed rate into the gasifier and ρ is
the density of the bed solids.
• In a typical bubbling bed, the bed voidage is ~0.7.
• The bed generally contains 5 to 8% (by weight) of
reacting char (xchar); the remaining solids are inert bed
materials.
• The bed height, Hbed , is known by dividing bed volume
by the bed area, Ab, which is known from chosen
superficial velocity
Fluidized bed….
Free board height
• Major carbon loss due to entrainment of unconverted
fine char particles
• The free board allows entrained particles to drop back
that provides a room for conversion of fine entrained
char particles
• It also helps to avoid excessive loss of bed material
• How can we determine the free board?
 From experience or through kinetic modeling
• A larger cross section area and a taller free board
increases the residence time of gas/char and reduce
entrainment
Design Optimization
• Completion of preliminary design => actual project
implementation starts=> process and engineering
• Process optimization tells the designer if the preliminary
design will give the best performance in terms of
efficiency and gas yield, and how this is related to the
operation and design parameters.
• One can approach optimization either through
experiments or through kinetic modeling.
• Process optimization enhances gasifier performance in
terms of the following indicators:
– Cold- and hot-gas efficiency
– Unconverted carbon and tar concentration in the product
gas
– Composition and heating value of the product gas
Performance and Operating Issues

• Gasifier performance is measured in terms


of both quality and quantity of gas
produced.
• The product quality is measured in terms of
heating value as well as amount of
desired product gas.
• The amount of biomass converted into gas
is expressed by gasification efficiency.
Performance and Operating
Issues(co..)
Cold-Gas Efficiency
• Cold-gas efficiency is the energy out put
over the energy input. If Mf kg of solid fuel
is gasified to produce Mg kg of product gas
with an LHV of Qg, the efficiency is
expressed as:
Performance and Operating
Issues(co..)
Hot-Gas Efficiency
• Sometimes gas is burned in a furnace or boiler
without being cooled, creating a greater
utilization of the energy. Therefore, by taking
the sensible heat of the hot gas into account,
the hot-gas efficiency, ηhg , can be defined as

where Tf is the gas temperature at the gasifier exit or at the burner’s entrance,
and To is the temperature of the fuel entering the gasifier.
The hot-gas efficiency assumes the heating of the unconverted char to be a loss.
Performance and Operating
Issues(co..)
Net Gasification Efficiency
• The enthalpy or energy content of the gasification
medium can be substantial, and so, for a rigorous
analysis, these inputs should be taken into consideration.
• At the same time, part of the input energy is returned
(energy credit) by the tar or oil produced as well as by
any recovery of the heat of vaporization in the product
gas.
– Total gross energy input = fuel energy content + heat
in gasifying mediums
– Net energy input = total energy input – energy
recovered through burning tar, oil, and condensation
of steam in the gas
Examples
1. Air steam gasifier data include the
mass composition of the feedstock: The dry air supply rate is 2.76 kg/kg of
component Mass % feed; the steam supply rate is 0.117 kg/kg of
C 66.5 feed; the moisture content is 0.01 kg of H2O
O 7 per kg of dry air; and the ambient
H 5.5 temperature is 20°C.
N 1 Find:
Moisture 7.3 A) The amount of gas produced per
Ash 12.7 kg of feed
B) The amou nt of moisture in the
LHV=28.4 MJ/kg product gas
and the volume composition of the C) The carbon conversion efficiency
product gas is given as: D) The cold-gas efficiency
E) If the gas produced by the gasifier is
component volume % supplied directly to a burner at the
CO 27.5 gasifier exit temperature, 900 °C, to be
CO2 3.5 burnt for co-firing in a boiler find the
CH4 2.5 hot-gas efficiency of the gasifier.
H2 15 (page 219 example 6.3 and page 222 example 6.4:Prabir
Basu: Biomass Gasification and Pyrolysis Practical Design and
N2 51.5 Theory)
Cont….
2. In most steam-fed gasifiers, a large amount
of steam remains unutilized. For the given
problem, Find
A. The product gas produced
B. The amount of unutilized steam.
C. The net gasification efficiency of a fixed
bed gasifier that uses steam and oxygen to
gasify grape wastes (HHV = 21,800 kJ/kg).
Cont…
• Ultimate and proximate
• The product gas composition analysis of biomass (mass%)
(mass%)
Proximate A Ultimate A
Component Mass%
Ash 4.2 Carbon 55.59
CO 31.8
Volatile 70.4 Hydrogen 5.83
H2 3.1 matter
CO2 38.2 Fixed 21.4 Nitrogen 2.09
carbon
CH4 1.2
Moisture 4.0 Sulfur 0.21
C3H8 0.9
Oxygen 32.08
N2 1
Ash 4.2
H2O 44.8

HHV product gas= 8.78MJ/kg


Cont….
• The total fuel feed rate is 25 kg/s; the oxygen feed rate is 5.3 kg/s. The
steam is fed into the gasifier at a rate of 27 kg/s at 180 °C and 5 bars of
pressure. The product contains dry gas, condensable moisture, and tar.
The tar production rate is 1.3 kg/s and is analyzed to contain 85%
carbon and 15% hydrogen by weight. The heating value of the tar is
42,000 kJ/kg. The oxygen is produced from air using an oxygen-
separation unit (OSU) that consumes 4000 kJ of energy/kg of the
oxygen produced (assume full conversion of char). Find the amount of
product gas produced and the fraction of steam that
remains unutilized.

(Example 6.5 page 223: Prabir Basu: Biomass Gasification and Pyrolysis
Practical Design and Theory)

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