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Chapter 4 - 2
Chapter 4 - 2
Gasifier Design
Ash
Design of Gasifiers…
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.)
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
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
after this subtract the oxygen content of the fule S 32.3 1.0078125 1.008 32.25
=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.)
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.)
Cross-draft 1250-1500
Down-draft Up to 1000
Up-draft Up to 900
Design of Gasifiers (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 :
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 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
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
(Example 6.5 page 223: Prabir Basu: Biomass Gasification and Pyrolysis
Practical Design and Theory)