Proceedings of

2000 International Joint Power Generation Conference

Miami Beach, Florida, July 23-26, 2000

IJPGC2000-15077

R & D on a Micro-gasifier

for On-site Gasification

of Solid Wastes

Tomoyuki T a k i y a * , J u n n o s u k e Ando*, K u n i o Yoshikawa *,**

* D e p a r t m e n t of Environmental Science and Technology
Tokyo Institute of Technology
4259 Nagatsuta, Midori-ku, Yokohama 226-8502, Japan
Tel: +81-45-924-5507, Fax: +81-45-924-5518, E-mail: t-takiya@depe.titech.ac.jp
** CREST, J a p a n Science and Technology Corporation

ABSTRACT

the heating value of the reformed gas

compared with the pyrolysis gas.

This paper proposes an innovative

micro-gasification system for solid wastes
whose name is the STAR-MEET system.

1. I N T R O D U C T I O N

This system employs a low temperature

pyrolizer combined with a high temperature

According to the resolution of COP-III

reformer using high temperature steam/air

Kyoto Conference in 1997, Japan has to

mixture generated by syngas. Preliminary

suppress the CO2 emission which requires

experiments of the STAR-MEET system has

us radical energy conservation. At present,

been done for three months continuously

lot of energy and

except week ends, where various industrial

transportation, treatment, incineration and

wastes are tested including waste wood

final disposal of various wastes produced in

chips,

wastes,

our economic activities. Due to tightening of

chicken droppings, waste rubber and car

environmental regulation, incineration and

shredder dust. Important findings are: by

disposal of wastes are becoming more and

injecting high temperature

air into the

more difficult and expensive. Therefore, as

pyrolyser, significant increase of the heating

shown in Fig. 1, if we can install a relatively

value of the pyrolysis gas was observed; and

small scale plant which extracts energy and

using high temperature steam/air mixture

resources contained in wastes as well as

as

almost

treating wastes at the site where wastes are

complete reforming of the tar component

produced, environmental and economical

has been done with m i n i m u m decrease of

benefits are significant.

an

waste

plastics,

oxidant

for

medical

reforming,

money is used

for

Copyright (C) 2000 by ASME

.......

Sale
IProduct
l

Sale
Construction
Material

...........................

-t .........

......... ::i:!:
Sale ........ .........
Fig.1

F u t u r e zero emission production system

The purpose of the p r e s e n t study is to

high t e m p e r a t u r e steam/air mixture, we can

clarify

raise

technical

feasibility

of

the

the

pyrolysis

temperature

with

microgasification system which well fits the

suppressed

above requirement.

increases the h e a t i n g value of the pyrolysis

gas.

The

air
metal

supply.
and

This
ash

effectively
components

contained m solid wastes will be left in the

pyrolyser
2. S Y S T E M

as a solid residue, which can be removed

during or after the pyrolysis process. T h u s

Figure 2 shows the scheme of the

STAR-MEET

micro-gasification

we can minimize the ash loading in the

system

pyrolysis gas.

proposed here. This system employs the

ST__.eam/Air Reforming
E nthalpy
wastes

Extraction

are

fed into

type

_Muti-staged

Technology.
a

batch

Solid

type

or

continuous type low t e m p e r a t u r e pyrolizer

with the operating t e m p e r a t u r e of 3 0 0 ~
600 C .
pyrolysis

Thermal
is

energy

supplied

required
from

for

partial

combustion of solid fuels or injection of high

t e m p e r a t u r e steam/air mixture. If we utilize

Copyright (C) 2000 by ASME

Normal Temp. Air

1
Fuel Gas, High Temp. Steam/
Air Generator
1000C
Steam/Air
IO0C Steam
Low
I Temp./
Gas
Clean up LSynga~ Boiler

i Gas Engine Fuel

Gas Turbin~Gas
Boiler
|

High
Pyrolysis
Temp'l
IG~ I
Thermal
Sjnga~ Reformer
Pyrolizer

Solid
Fuel

Ash ---I~Solidification

Fig.2

STAR-MEET system

On the other hand, the pyrolysis gas

contains
dioxin

tar
as

and
well

reactions to supply t h e r m a l energy required

soot components and

as

combustible

for the above reforming reactions.

clean

components such as CO, H2 and CH4. The

pyrolysis gas cannot be directly cooled and

purified because the tar c o m p o n e n t will

CnHm+(n+ 1/4m)O2-~nCO2+ 1/2mH20

02-~
1/202

CO2

(4)

--~ CO

(5)
(6)

solidify and clogging m a y occur. T h u s the

produced pyrolysis gas is introduced into a

If we utilize normal t e m p e r a t u r e air for

reformer to react with steam, where tar and

these

soot components of the pyrolysis gas is

a m o u n t of air to get high enough reforming

reformed into CO and H2 based on the

t e m p e r a t u r e above 800C

following reactions.

reactions (4) and (6). T h e n the heating value

reactions,

we

must

supply large
by promoting

of the reformed gas should inevitably be

C + CO2 ~ 2CO

(1)

m u c h lower t h a n t h a t of the pyrolysis gas

C+H20

(2)

because of large content of CO2 and N2. If

(3)

we employ pure oxygen or oxygen rich air to

~ CO+H2

CnHm + nH20 ~ nCO + (n+l/2m) H2

increase the h e a t i n g value of the reformed

B u t these reactions will only occur under

gas,

high t e m p e r a t u r e above 800C and they are

production unit and a large a m o u n t of

endothermic. So we cannot expect these

energy is consumed for oxygen production.

reactions to occur by merely injecting 100C

On the contrary, the STAR-MEET system

steam. T h u s normally, we mix oxygen or air

injects high t e m p e r a t u r e steam/air mixture

into steam to induce following exothermic

into the pyrolysis gas to carry out reforming

we

need

an

expensive

oxygen

Copyright (C) 2000 by ASME

of tar and soot components with m i n i m u m

reduction of the

heating value

of the

The

STAR-MEET

system

is

reformed gas. Thus we can obtain reformed

appropriate for local small-scale solid fuel

gas with high heating value using a very

gasification,

compact reformer.

should be minimized.

where

operating

manpower

Produced high temperature reformed

gas (syngas) is cooled in the waste heat
recovery boiler and is used as a fuel gas for

3.

power generation, process heating or steam

PROCEDURE

EXPERIMENTAL

FACILITY

AND

generation after being cleaned-up. High

temperature

steam/air mixture used for

3.1

pyrolysis and/or reforming is produced by

Outline

of

the

STAR-MEET

Experimental Facility

combustion of part of cleaned-up syngas in a

regenerative

type

high

temperature

This experimental facility was setup to

preheater 1.

demonstrate production of clean syngas

with high heating value by the reforming

This

STAR-MEET

system

has

reaction between pyrolysis gas generated

following distinct advantages.

from a low temperature pyrolyser and high

1) Mmost no pre-treatment is required for

temperature

steam/air

mixture

(high

most of solid fuels which is quite

temperature reforming expeiment). In order

attractive

to

for

on-site

small

scale

increase

the

heating

value

of the

gasification or treatment of hazardous

pyrolysis gas, trial was made to inject high

wastes such as medical and radioactive.

temperature steam/air mixture directly into

2) The system can be designed to be very

the

compact and fully automatic controlled,

pyrolyser

also

(high

temperature

pyrolysis experiment).

which is appropriate for installation in

commercial, industrial and residential
buildings, hotels, hospitals,

etc. The

system can also be designed to be

movable by a truck.
3) Dioxin contained in pyrolysis gas can be
completely decomposed in

the

high

temperature reforming reactor.

4) Most of ash in solid fuels are left in the
pyrohzer, which results in very small
amount of dust in syngas.

Copyright (C) 2000 by ASME

Chimney

Exhaustair ejectorT7~ L ~

Combustionduct
/'RefT~rming
d uT4
ct5
$3 $2

l T2

Air

S1

T1 P1

~ower 1
HighTemp.~
Staam

~
~

[~-"
Pyrolyser

Exhaust

Air

T9

\'Blower 1
Fig.3 Setup for high temperature reforming experiments

j Chimney
_-------Burner2
,T8
Combustionduct
/ /Reformingduct

Exha
T1 r n v~ ~

Bo

i"

l ,/ ~5 /4
rl-~~ I

6 S3 S2 T2

Blower1
Hightemp.~

2215

z
Boiler

Fig.4 Setup for high temperature pyrolysis experiments

Copyright (C) 2000 by ASME

Figures 3 and 4 show the experimental

3.2 Measurements

setup used for high temperature reforming

experiments

and

high

pyrolysis experiments,

Following items were measured during

temperature

experiments.

respectively. Gas

sampling locations (S1-$3),

temperature

measurement locations (T1-T9), pressure

(1) Composition of gases

measurement location (P1) and flow rate

During high temperature reforming

measurement location of high temperature

experiments, the gas composition of the

steam/air mixture (F1) are also shown in

pyrolysis gas at the exit of the pyrolyser

these figures.

and that of the reformed gas within the

For

high

temperature

reforming

reforming duct were measured. In the

experiments shown in Fig.3, solid wastes

course of gas sampling, the tar and soot

were put into the pyrolyser where pyrolysis

components

was done using normal temperature air

composition (H2, 02, N2, CH4, CO, CO2,

supplied from the Blower 1. The pyrolysis

C2H4, C2H6)of the pyrolysis and reformed

gas was introduced into the reforming duct

gases

into which high temperature

chromatography.

steam/air

were

were

pre-cut.

measured

Then

using

the

gas

mixture of about 800C produced by the

high temperature preheater using propane

(2) Gas temperature

gas as a fuel was injected. Then the

reformed gas
combustion

was
duct

introduced into
where

Using thermocouples, gas temperature

the

at various locations were measured.

secondary

combustion was done to conduct complete

(3) Volume flow rates

combustion of the syngas. In the case of

Volume

high temperature pyrolysis experiments

temperature

shown in Fig.4, high temperature steam/air

measured by a high temperature pitot

mixture of about 600C was fed into the

tube installed at the exit of the high

pyrolyser to promote pyrolysis process.

temperature preheater. Volume flow rate

Then

directly

of air-supplied to the pyrolyser and the

introduced into the combustion duct without

combustion duct were determined by

reforming, where complete combustion was

recorded rotational speed of the blowers.

the

pyrolysis

gas

was

flow

rate

steam/air

of

mixture

high
was

done.

6
6

Copyright (C) 2000 by ASME

debris of ABS while the rest was leather.

3.3 Tested Solid Wastes

The ash content was high (mostly glass

Gasification tests were done for three

months

fiber) so t h a t the heating value (LHV) was

continuously except week ends,

as low as t h a t of wood chips.

where various industrial wastes were tested

Waste Rubber

including waste wood chips, waste plastics,

Waste rubber contained metal fittings,

medical wastes, chicken droppings, waster

whose weight percentage is more than 60%.

rubber and car shredder dust. Here typical

Composition analysis was done only for

results for waste plastics and waste rubber

rubber component.

will be reported.
Tables 1 and 2 show the physical
The principal properties of both materials

composition and the composition analysis

were as follows.

data of each material.

Waste Plastics
About 80% of the waste plastics were
composed

of helmet

shaped

FRP

and

Table 1 Physical composition

Material

Water
contents

Properties

(%)

Weight percentage
of solid residue

(%)

Specific
weight
(Ash)

Wet base
Waste plastics

Waste rubber

300mm helmets and

10mm corner FRP
Crashed FRP 80%
Crashed leather 20%
40mm shaped cylinder
Weight percentage of metal
fittings is more than 50%

25.9

0.16
(0.24)

61.1

0.52
(0.32)

Copyright (C) 2000 by ASME

Table 2 Composition analysis

Analysis item
Water content (%)
Solid content (%)
Ash content (%)
Dry base
Volatile content (%)
Dry base

Waste plastics
0.76
99.24

Waste rubber
1.20
98.88

29.91

4.80

60.27

67.95

44.2

82.4

3.3

8.6

0.03

0.03

22.43

2.91

<0.01

1.13

0.13

0.13

17.00

38.47

16.24

36.13

c (%)

Dry base
H (%)
Dry base
N (%)
Dry base
0 (%)
Dry base
Volatile sulfur (%)
Dry base
Volatile chlorine (%)
Dry base
High heating value (HHV)
(MJ/kg)
Dry base
Low heating value (LHV)
(MJ/kg)
Dry base

4. EXPERIMENTAL RESULTS
4.1 Pyrolysis Performance
The target of the STAR-MEET system

High

heating value

(HHV)

of the

is to produce clean fuel gas with high

pyrolysis gas

heating value from wastes efficiently while

components in high temperature reforming

suppressing dioxin emissions. Therefore,

experiments

was

important things to verify the effectiveness

temperature

and

of the system are as follows: one is to raise

pyrolysis gas at the inlet of the reforming

heating value of the pyrolysis gas generated

duct, 2) temperature and volume flow rate

from the pyrolyser, and the other is, with

of high temperature

minimizing reduction of heating value of the

injected

reformed gas, to decompose tar and soot

temperature rise in the reforming duct, and

components

4) HHV of reformed gas determined by the

as

well

as

dioxin

into

flammable gases. This section deals with

pyrolysis

performance

and

into

containing tar
estimated

and
from

volume flow rate

the

soot
1)
of

steam/air mixture

reforming

duct,

3)

method described later.

reforming

In

performance.

high

temperature

pyrolysis

experiments, HHV of the pyrolysis gas was

estimated from 1) temperature and volume

Copyright (C) 2000 by ASME

flow rate of pyrolysis gas at the inlet of the

combustion duct, 2) volume flow rate of air
supplied

into

the

combustion duct,

1200

3)

o HiL4~Tm~mtum Air

"'

IO00

temperature rise in the combustion duct.

. Hillh T ~ p e ~ u ~ Air & S t .

l...............

800

~~

0 8
O%
o
4be ~o

Waste Plastics
The

experimental result

of waste

.~'%'~:"2,~':" . . : . a i r , : -

I 200

I- -

** * ~

plastics is shown in Fig.5. In this case, when

temperature

of the

pyrolyser

changes,

100

200

300

400

500

600

700

Pyrolysis Temperature [ ~

heating value of the pyrolysis gas is stable.

Fig.5

There is a significant rise of HHV due to

a function of pyrolysis temperature (waste

introduction of high temperature air, where

plastics)

Heating value of the pyrolysis gas as

volume flow rate of normal temperature air

and high temperature air is almost equal.
Introduction of high temperature steam has

1200

no particular effects.

oHid Tem~mt~

1000
o

Waste Rubber
The

800

'~ 600

experimental result

of waste

400

rubber is shown m Fig.6. In this case, as the

.?:,.e,';.7

200

temperature of the pyrolyser rises, HHV of

~^-

the pyrolysis gas increases. The rise of HHV

1O0

200

300

400

500

600

700

Pyrolys;s Temperature [ ' C ]

by introducing high temperature air (about

Fig.6

half

a function of pyrolysis temperature (waste

of

normal

remarkable,
temperature

temperature

especially
of

the

air)

when

pyrolyser

is

rubber)

the
is

Heating value of the pyrolysis gas as

low.
From the above results, we can say

Introduction of high temperature steam

shows some effects on increasing HHV of

that

using

high

temperature

the pyrolysis gas.

pyrolysis process is

quite

air

for

effective for

increasing HHV of the pyrolysis gas. In the

future pilot plant, all the air required for
the

pyrolysis

temperature
generated

process
air

using

should

which
waste

is
heat

be

high

preferably
of

high

temperature reformed gas. The effect of

adding high temperature steam is not so
clear yet.

Copyright (C) 2000 by ASME

4.2 Reforming Performance

both gases can be determined as [HHV

To reform the pyrolysis gas in the

(with tar and soot) - HHV(without tar and

reforming duct at the t e m p e r a t u r e about

soot)]. This HHV of tar and soot components

800C, t e m p e r a t u r e of the pyrolysis gas

in both gases were also plotted as a function

should be increased by partial combustion of

of the reforming t e m p e r a t u r e . If this HHV

flammable

value

components

of

the

low-temperature pyrolysis gas. So, although

is

small,

we

can

say

that

the

of

gas

reforming process works well.

heating value of the reformed gas should

always be lower t h a n t h a t of the pyrolysis

Waste Plastics

gas, reduction of heating value is expected

The

experimental

results

to be minimized by using high t e m p e r a t u r e

reforming using waste plastics are shown m

steam/air mixture as an oxidizer. And the

Figs. 7 and 8. In this case, at the reforming

use of high t e m p e r a t u r e steam/air mixture

t e m p e r a t u r e of 800C, HHV of the reformed

is

effective for promoting the reforming

gas is decreased to about 6 0 ~ 8 0 % of HHV

reaction, which should result in downsizing

of the pyrolysis gas. And in this reforming

of the reformer. In this experiment, HHV of

temperature, it can be seen from Fig.8 t h a t

the reformed gas is estimeted from

1)

there is no significant a m o u n t of tar and

t e m p e r a t u r e and volume flow rate of the

soot components left in the reformed gas.

reformed gas at the inlet of the combution

On

the

other

hand,

at

the

reforming

duct, 2) volume flow rate of secondary

temperature

combustion air supplied to the combustion

introducing

duct, and 3) t e m p e r a t u r e of the secondary

remarkable, and significant rise of HHV of

combustion gas. Then, the ratio between

the reformed gas can be observed.

over 60 0C,
high

the effect of

temperature

steam

is

HHV of the reformed gas and HHV of the

pyrolysis gas is plotted as a function of
t e m p e r a t u r e of the reforming duct. It is
expected t h a t this ratio reaches unity when

we decrease the reforming t e m p e r a t u r e and

1.2

% 1

it decreases w h e n we increase the reforming

;2

- ,.::.,....

~o8

t e m p e r a t u r e . In this plotting, the case using

006
E

only high t e m p e r a t u r e air and the case

using high t e m p e r a t u r e steam/air mixture

04

o.2
I

is distinguished. In addition, composition of

200

400

600

o.~T.__
- H~shTewemzum ~~r
r & Stem i

Reforming T o m l ~ r a t u r o

pyrolysis

gas

removing tar

and

reformed

gas

after

Fig.7

and soot components was

800

1000

1200

~]

Heating value of the reformed gas as

a function of the reforming t e m p e r a t u r e

m e a s u r e d by using a gas chromatography,

(waste plastics)

from which we can calculate HHV of both

gases without tar and soot components.
Then, HHV of tar and soot components in
10
10

Copyright (C) 2000 by ASME

600
, ~ . ~ .

o Refor~d ~

GllmhT ~ e m ~

Air)

1.4

500

o HiS Tem~mturl Air

I -Hillh . . . . . . . . . .

1.2

4oo

~o~

~300

~200

~ 04

~100
i

400
600
R e f o ~ ng Temperature

200

800

1000

1200

200

400

0
0

['C"

Reformln8

Fig.8

Heating

value

of tar

and

Fig.9

soot

of

the

reforming

lfX~l

1299

Heating value of the reformed gas as

a function of the reforming temperature

components left in the reformed gas as a

function

600
B00
Temperature ['C]

(waste rubber)

temperature

(waste plastics)

Waste Rubber
The

experimental

500

,~4oo

results

of

gas

8~

reforming using waste rubber are shown in

200
t

Figs. 9 and 10. In this case, at the reforming

0

t e m p e r a t u r e of 800C, HHV of the reformed

gas is decreased to about 70% of HHV of the

i
200

Fig. 10

pyrolysis gas. Although reduction of tar

I
I
i
400
600
800
Reformirt8 T e m p e e a t ~ [~C~

I
1000

Heating value of tar

1200

and soot

components left in the reformed gas as a

components due to rise of the reforming

function

t e m p e r a t u r e cannot be seen clearly from

of the

reforming

temperature

(waste rubber)

Fig.10, our observation showed t h a t the

sampled gas became cleaner by reforming.

F r o m the above results, we can say

At the reforming t e m p e r a t u r e over 600C,

that

introduction of high t e m p e r a t u r e steam is

using

high

temperature

steam/air

mixture as an oxidant of the reforming

quite effective for increasing HHV of the

process is effective for keeping the heating

reformed

value

gas.

of the reformed gas as high as

possible. High t e m p e r a t u r e reforming is

suitable for decomposition of tar and soot
components in the pyrolysis gas, which is
also effective for decomposition of dioxin in
the pyrolysis gas.

11
11

Copyright (C) 2000 by ASME

the pyrolysis gas.

5. SUMMARY
An

innovative

micro-gasification

system called STAR-MEET

system

for

on-site treatment of solid wastes is proposed.

This system combines low temperature
pyrolysis with high temperature reforming.
Preliminary

experiments

show

that

introduction of high temperature air into

the pyrolyser is effective for increasing the
heating value of the pyrolysis gas. It is also
shown

that

using

high

temperature

steam/air mixture as an oxidant of the

reforming process is effective for increasing
the heating value of the reformed gas while
realizing almost complete decomposition of
tar and soot components in the reformed
gas.
We are planning to install a pilot plant
of the STAR-MEET system, through which
an early commercialization of the system is
expected.

REFERENCES
. Y. Koyama, K. Yoshikawa, S. Mochida
and M. Kasahara, "Gasification of Coal
and

Solid

Wastes

Using

High

Temperature Air (Part III: Performance

Demonstration
Temperature

of
Air

Compact

High

Preheater),

Proc.

ECOS'99, pp.411-414, 1999.

12
12

Copyright (C) 2000 by ASME