Atan Tuahta (1206227535), Husnul Fajri (1206224994),

M. Fatah Karyadi (1206263370), Paramitha Dona (1206263383),

Satrio Bimo Wijardono (1206220636)

BIOMASS GASIFICATION
FOR NATURAL GAS
SUBSTITUTION IN IRON
PLANTS

Assignment 1 Chemical Plant Design

INTRODUCTION

Background
Biomass gasification plant background:
Increasing demand of iron
Limitation of gasoline, coal, LNG usage
High number of biomass production

Basic Theory
Main reaction of Iron Processing:
Iron: Main Product

Iron Ore: collected from

mining activity

Carbon Monoxide: reductor

from coal or Natural Gas
Occurs at high temperature only

Basic Theory
Biomass: biological material derived from living or rece
ntly linving organisms.
Major components in Biomass: Cellulose, Hemicelullos
e, Lignin

Market and Capacity Analysis

50
45
40
35
30

Production (million tonnes) 25

20
15
10
5
0
2005 2010 2015 2020 2025 2030 20352040 2045 2050

Year
Demand

Supply

Gap: 2.8 million tonnes.

Current utilization: 0.75
million tonnes (estimate d
ata)
Capacity: 2 million tonnes

Raw Material Analysis

Parameter

Rice Husks

Production

Palm Oil EFB

-

capacity
Availability

Notes
Each year, rice husks production is more than
palm oil EFB

in

Indonesia

Rice husk can be found in almost everywhere in

Indonesia, while EFB is dominantly founded in
Sumatera and Kalimantan

Current usage

It has been settled that EFB is used primarily for

biodiesel, while rice husk is mainly burned away

Plant Location Analysis

Plant location: Cilegon, Banten.
Analysis Parameters:
Electricity: 2 power plants nearby with capacity up to 2000
MW
Availability of Raw Material: can be found in Java Island
Access to Plant: road transportation

PROCESS SELECTION

Block Flow Diagram

Background

Analysis

Process
Synthesis
Mass and
Energy
Balance

Biomass Gasification

GRINDING

DRYING

GASIFICATION

Pyrolysis

Gasification

PARTICLE
REMOVAL

GRINDING
The process of
reducing the particle
size of the processed
material from the
shape of large
converted into a
smaller size

DRYING
The biomass needs to be
dried prior to gasification to
improve efficiency.
Rotary dryers are the most
common type of biomass
dryer.
In the rotary dryer, the
biomass is passed through a
rotating drum where it comes
in contact with hot gases.

GASIFICATION
Gasification is a thermal
process that breaks down
the chemical bonds in the
fuel in order to produce an
energy rich gas.
The process is an
endothermic process which
requires external heat.
Divided into two steps

Gasification

Pyrolysis

Low Temperature
Doesnt require
Oxygen

Gasification

High Temperature
Require Oxygen

REACTION

PARTIAL OXIDATION

Combustion

Gasifying agent in partial

oxidation is oxygen, whic
h may be supplied as pure
oxygen or as air.

CO2 GASIFICATION

Endothermic

Requires high temperature

(for fast reaction) and high
pressure (fir high reactant
concentrations) for
significant conversion.

STEAM GASIFICATION

HYDROGASIFICATION

Direct addition of hydrogen to coal

under high pressure forms
methane.

This reaction is exothermic and is

thermodynamically favored at low
temperatures (T < 670C), unlike
both steam and CO2 gasification
reactions.

Similar with CO2 Gasification

Typically combined with other
gasification reactions in practi
cal applications.

Reactor Types

Process Selection for Biomass Gasification

Gasify pulverized fuel particles suspended in a

stream of oxygen (or air) and steam.

In entrained-bed reactor, methane content is

very low therefore doesnt require specific
fractionation.

Generally use oxygen as the oxidant and

operate at high temperatures.

Temperature is well above ash-slagging

conditions, to ensure hugh carbon conversion.

Ash in the coal melts at the high operating

temperature of the gasifier and is removed as
liquid slag.

Entrained Flow
Gasifier

Particle Removal

To remove the largest

particles and returns them to
the gasifier.

Works on the principle of

creating a high-speed spiral
airflow that applies centrifugal
force to remove particles.

Process Selection In Iron Plant

Blast Furnace
Midrex Process
Hylsa

Blast Furnace
Using coal as a fuel for this process
Produce pig iron from iron ore by the r
educing action of carbon (supplied as
coke) at a high temperature
This process has a very high temperatu
re of about 1,650 C (3,000 F) that pr
oduces the liquid iron and slag
Modern blast furnaces range in size fr
om 20 to 35 m (70 to 120 feet), have
hearth diameters of 6 to 14 m (20 to 4
5 feet)

MIDREX Process

The desired reducing gas temp

erature is typically in the range
of 900C
Using natural gas and agglome
rated iron ore makes the proce
ss simple
The product, DRI, is typically 9
0% to 94% iron
Plants can operate at a wide sp
ectrum of hydrogen to carbon
monoxide ratios (0.5 to 3.5)

Hylsa

In the HYL II process, reducin

g gas is generated by reformi
ng natural gas with excess st
eam
The HYL process is a cyclical b
atch operation
The energy consumption in
most recent plants is 14.9 GJ/
tonne (12.8 MBtu/ton) of 9
0% reduced DRI

Production during the first six

months of operation has been
at capacity, with metallization l
evels of 95% and carbon of
4% as iron carbide (cementite)
This process has a high temper
ature of about 700 C that pro
duces the iron sponge

Process Selection Scoring

Process Description (Iron Processing)

Grinding: minerals are made into fine particles (< 0.1
mm)
Sintering: agglomeration of fine particles by combustio
n
MIDREX Process: Direct Reduced Iron (DRI) Production
Electric Arc Furnace: Produce batchs of molten steel
Casting: Molten steel solidification

Iron Processing

MASS AND ENERGY

BALANCE

Mass Balance - Overall

Component
Ash
Cellulose
Hemicellulose
Lignin
Tar
CH4
Ethane
CO
CO2
H2
H2O
Fe2O3
Fe
TOTAL

In
0
36.3
11.8
18.9
0
0
0
0
0
0
33
66.38
0
166.38

Out
12.598
0
0
0
5.2386
7.3088
0.43255
0
71.854
1.1952
21.26
0
46.48
166.3672

BASIS: 100 kg/h

Vapour
H2O

Raw Material
Cellulose
Hemicellulose
Lignin
H2O

Process
Tar
Ash

Waste

Product
CH4
Ethane
CO
CO2
H2
H2 O
Fe2O3
Fe

Mass Balance - Grinding

Component
Ash
Cellulose
Hemicellulose
Lignin
Tar
CH4
Ethane
CO
CO2
H2
H2O
Fe2O3
Fe
TOTAL

Raw Material
0
36.3
11.8
18.9
0
0
0
0
0
0
33
0
0
100

Drying Feed
0
36.3
11.8
18.9
0
0
0
0
0
0
33
0
0
100

Raw Material
Cellulose
Hemicellulose
Lignin
H2O

Grinder

Drying Feed
Cellulose
Hemicellulose
Lignin
H2 O

Mass Balance - Drying

Component
Ash
Cellulose
Hemicellulose
Lignin
Tar
CH4
Ethane
CO
CO2
H2
H2O
Fe2O3
Fe
TOTAL

Drying
Feed
0
36.3
11.8
18.9
0
0
0
0
0
0
33
0
0
100

Gasfier
Feed
0
36.3
11.8
18.9
0
0
0
0
0
0
11.74
0
0
78.74

Vapour
0
0
0
0
0
0
0
0
0
0
21.26
0
0
21.26

Vapour
H2 O

Drying Feed
Cellulose
Hemicellulose
Lignin
H2 O

Dryer

Gasifier Feed
Cellulose
Hemicellulose
Lignin
H2O

Mass Balance - Gasification

Component
Ash
Cellulose
Hemicellulose
Lignin
Tar
CH4
Ethane
CO
CO2
H2
H2O
Fe2O3
Fe
TOTAL

Gasifier Feed
0
36.3
11.8
18.9
0
0
0
0
0
0
11.74
0
0
78.74

Output Gas
12.598
0
0
0
5.2386
7.3088
0.43255
34.848
17.118
1.1952
0
0
0
78.74

Gasifier Feed
Cellulose
Hemicellulose
Lignin
H2O

Gasifier

Output Gas
Ash
Tar
CH4
Ethane
CO
CO2
H2

Mass Balance Particle Removal

Output
Syn-gas
Gas
0
Ash
12.598
0
0
Cellulose
0
0
Hemicellulose
0
0
Lignin
Tar
5.2386 5.2386
CH4
7.3088 7.3088
Ethane
0.43255 0.43255
CO
34.848 34.848
CO2
17.118 17.118
H2
1.1952 1.1952
0
H2O
0
Fe2O3
0
0
Fe
0
0
TOTAL
78.74
66.14
Component

Solid
12.60
0
0
0
0
0
0
0
0
0
0
0
0
12.60

Output Gas
Ash
Tar
CH4
Ethane
CO
CO2
H2

Particle
Removal
Ash

Solid

Syn-gas
Tar
CH4
Ethane
CO
CO2
H2

Mass Balance MIDREX Process

Component
Ash
Cellulose
Hemicellulose
Lignin
Tar
CH4
Ethane
CO
CO2
H2
H2O
Fe2O3
Fe
TOTAL

Syn-gas
0
0
0
0
5.2386
7.3088
0.43255
34.848
17.118
1.1952
0
0
0
66.14

Iron Ore
0
0
0
0
0
0
0
0
0
0
0
66.38
0
66.38

Iron
0
0
0
0
5.2386
7.3088
0.43255
0
71.85
1.20
0
0
46.48
132.51

Iron Ore
Fe2O3

Syn-gas
Tar
CH4
Ethane
CO
CO2
H2

Shaft
Furnace

Iron
Tar
CH4
Ethane
CO2
H2
Fe

Energy Balance - Drying

Qin
Qout
Component
Ash
0
0
Cellulose
1,270.5
3,557.4
Hemicellulose 392.35 1,098.58
807.97
Lignin
5 2,262.33
Tar
0
0
CH4
0
0
Ethane
0
0
CO
0
0
CO2
0
0
H2
0
0
H2O
1,386
3,880.8
Fe2O3
0
0
Fe
0
0

Vapour
H2 O

Drying Feed

Dryer

T = 25oC

Gasifier Feed
T = 70oC

Energy Balance - Gasification

Component
Ash
Cellulose
Hemicellulose
Lignin
Tar
CH4
Ethane
CO
CO2
H2
H2O
Fe2O3
Fe
TOTAL

Qin
0
3,557.4
1,098.58
2,262.33
0
0
0
0
0
0
1,380.624
0
0
8,298.934

Qout
14,941.18
0
0
0
6,212.959
19,216.3
856.9681
43,490.3
28,758.24
20,366.21
0
0
0
133,842.2

Gasifier Feed

Gasifier

T = 70oC

Output Gas
T = 1200oC

Energy Balance MIDREX Process

Component
Ash
Cellulose
Hemicellulose
Lignin
Tar
CH4
Ethane
CO
CO2
H2
H2O
Fe2O3
Fe
TOTAL

Qin
0
0
0
0
2070,986
6405,432
285,656
14496,77
9586,08
6788,736
0
2738042
0
2,777,676

Qout
0
0
0
0
6212,959
19216,3
856,9681
0
120714,7
20366,21
0
0
25099,2
192,466.4

Iron Ore
Fe2O3

Shaft
Furnace

Syn-gas
T = 400oC

Iron
T = 1200oC

Energy Efficiency
Unit Operation

Energy In

Energy Out

Dryer

3,856.825

10,799.11

Gasifier

8,298.934

133,842.2

Shaft Furnace

1,777,676

192,466.4

Total

2,789,832

337,107.6

Conclusion

Biomass has great potential in Indonesia yet its added value is not widely utilized. Many solutions
are offered, in which one of the is gasification as natural gas substitution in iron plants
There are numerous sources for biomass raw material . For our plant, rice husks is used because
of many considerations like production capacity, availability, and current usage.
The gasification plant will be located in Cilegon, Banten with the production capacity of 2 million
tonnes per year.
The main processes for our plant are grinding, drying, gasification, particle removal, and reductio
n of iron ore. The technology used is entrained flow gasifier to produce high level of CO.
Simulation using ASPEN HYSYS is used in modelling the process. It is observed that H 2 and CO ar
e the most abundant component in syn-gas with the H2:CO ratio is apporoximately 1:2
It is observed that from 100 kg of biomass, 78.24 kg of syn-gas is produced. This number of syngas will be used to reduce iron ore to obtain 46.48 kg of iron.
It is observed that the mass efficiency of the plant is 78.24&, while the energy efficiency is 12%

THANK YOU