Biomms and Eioenwg~ Vol. 13, No. 3. pp. 141-146.

1997
(7 1997 Published by Elsevier Science Ltd. All rights reserved
Pergamon
Printed in Great Britain
PII: SO961-9534(97)000147 0961-9534/97 $17.00 + 0.00

SUGARCANE LEAF-BAGASSE GASIFIERS FOR

INDUSTRIAL HEATING APPLICATIONS

RAJEEV JORAPUR AND ANIL K. RAJVANSHI

Nimbkar Agricultural Research Institute (NARI), P. B. 44, Phaltan, -415 523, Maharashtra, India

(Receirred 20 Nocember 1996; rerised 18 March 1997; accepted I I April 1997)

Abstract-This paper reports the commercial-scale (1080 MJ h-‘) development of a gasification system
using low-density biomass, for thermal applications. The gasifier can handle fuels such as sugarcane leaves
and bagasse, bajra stalks, sweet sorghum stalks and bagasse etc. The system was tested for > 700 h under
laboratory conditions at 288-1080 MJ h-’ output levels. The HHV of the gas was 3.56-4.82 MJ mm’
(s.t.p.). The system also produces char, u 24wt% of the original fuel. It can be briquetted to form an
excellent fuel for wood stoves or can be used as a soil conditioner. After successful laboratory trial, the
system was also tested at a metallurgical company, where it was retrofitted to an oil-fired furnace for
baking speciality ceramics. The furnace was operated exclusively on the gasification system and the
product quality was on a par with, if not better than, that obtained during oil-fired operation. The
economics of the system are also presented. C> 1997 Published by Elsevier Science Ltd

Keywords--Biomass; gasification; thermal applications: low-density biomass; sugarcane leaves; bagasse

1. INTRODUCTION elsewhere.4,5 However, all of them use either

wood, wood waste or rice husks as the fuel for
Rapid rural industrialisation in India has
gasification. This paper reports the development
resulted in an ever-increasing demand for
of a commercial-scale (1080 MJ h-‘) model of a
process heat and steam. Most of these industries
gasifier which can handle low-density and leafy
are in the metallurgical and food processing
biomass such as sugarcane leaves and bagasse,
sectors and have to use petroleum fuels such as
and its subsequent tests in an actual user
furnace oil, light diesel oil (LDO) or diesel to
industry. Its techno-economic feasibility is also
meet their energy demands. However, due to
analysed.
uncertain supplies and high cost of these fuels,
there is an urgent need for other sources of
energy. 2. EXPERIMENTAL
India produces annually - 320 million
tonnes of agricultural residues comprising 2.1. GasiJication system design
mainly rice husks, paddy straw, sugarcane Certain critical engineering design norms of
leaves and wheat residues.’ It is guesstimated the gasification system were first developed on
that about a third of this, or - 100 million a laboratory-scale model and were then
tonnes of residues, is not being utilised and is validated on a bench-scale model.‘.’ These
disposed of by burning in the open fields. These norms were then used to design a fully fledged
solid fuels can be effectively harnessed by commercial-scale system with a thermal output
converting them to a gaseous combustible fuel of 1080 MJ h-‘. This system (presently installed
termed “producer gas” in suitably designed on the NARI campus) is seen in Fig. 1.
reactors. This producer gas, which has a gross It comprises a reactor, a gas conditioning
calorific value of 3.5-5 MJ mm’ (s.t.p.), consists system, a biomass feeding system and instru-
mainly of carbon monoxide (25~01%) and mentation and controls. A schematic diagram of
hydrogen (15-20~01%). It can be burnt in this system is shown in Fig. 2. The salient
suitable burners with flame temperatures ex- features of these components are described
ceeding 1000°C and can be used for industrial below.
heating applications. Reactor: This was a downdraft, throatless
There are reports of gasifiers being used for and open-top reactor with an internal diameter
thermal applications both ig India2,3 and of 75 cm and an active bed height of 1.25 m. It

141
142 R. JORAPURand A. K. RAJVANSHI

Fig. I. NARI gasification system for thermal applications (I 080 MJ h-‘): R, reactor; T. cooling/cleaning
train; C, biomass conveyor.

was designed for a heavy-duty cycle of the combustible gas did not escape. Thus this
7500 h year’ operation. High-temperature-re- design is very environment-friendly. The char-
sistant firebricks conforming to IS 8 grade were ash from the coarse settler and the cyclone was
used for the hot face, followed by cold-face collected in barrels and emptied into an ash pit
insulation. every 45 min. This char-ash, with typically a
Gas conditioning system: A completely dry gross calorific value of 18.9 MJ kg-‘, can be
dust collection system eliminated altogether the briquetted to form an excellent fuel, or can be
problem of wastewater. This consisted of a used as a soil conditioner.8,9
high-temperature char-ash coarse settler and a Biomass feeding system: This consisted of a
high-efficiency cyclone separator. A specially scraper drag conveyor and a hopper to convey
designed high-temperature-resistant induced- the biomass fuel from the storage pile to the
draught fan ensured that the entire system was reactor. The conveyor was completely enclosed.
under negative pressure so that in the event of Instrumentation and control system: A pro-
leaks, outside air was sucked into the system but grammable logic controller (PLC)-based control

Fig. 2. Schematic diagram of sugarcane leaf-bagasse gasification system: A, biomass from storage piles;
B, hopper; C. conveyor; D, refractory; E, char collector; F, cyclone; G, air; H, furnace (1080 MJ h-l);
1, chimney; R, reactor.
 Sugarcane leaf-bagasse gasihers for industrial heating applications 143

sorghum stalks and bagasse, bajra stalks etc.

The physical properties of sugarcane leaves and
bagasse under the actual operating conditions of
the gasifier are given in Table I .’ Sugarcane
leaves are normally l-2 m long. They were
chopped into I-10 cm long particles using a
2.3 kW chaff cutter. Bagasse as available from
the sugar factories was almost powdery and did
not require any size reduction. However, it
contained typically - 50wt% moisture, so it
needed to be air-dried before it could be used in
the gasifier.
Table 2 gives the proximate and ultimate
analyses of these fuels.‘- I”

3. RESULTS AND DISCUSSION

The gasification system was extensively tested

at NARI on the above fuels. A synopsis of the
results is given in Table 3.
The gasifier was operated on both sugarcane
leaves and bagdsse either interchangeably or
mixed in any proportion. The output was in the
range 288-1080 MJ h-’ (thermal). It is seen
Fig. 3. PLC-based control system.
from Table 3 that the steady-state temperature
of the gas at the inlet of the burner was
system, seen in Fig. 3, was designed to take > 300°C and so there was no condensation and
automatic corrective actions under certain accumulation of tars and particulate matter in
critical conditions. Thus the biomass feeding the equipment and piping even after 700 h of
and ash removal rates were fully controlled by operation with mainly cold starts. In most
this system. It also helped the operator in gasifiers, water or oil is used to cool the gas
troubleshooting by monitoring temperatures at before it is fed to the burner or the prime mover.
various critical points in the gasification system. This results in condensation of the tar in the gas
Automatic burner sequence controllers were stream. In the presence of particulate matter,
provided for ignition of the producer gas. the tar and the particles tend to accumulate in
The gasification system was extremely simple the pipes and equipment, choking them. The
to operate. A cold start took - 10-l 5 min gasifier system then has to be shut down and the
whereas a hot start was effected in < 5 min. piping/equipment cleaned before it can be
Only two operators per 8 h shift were required operated again. In the present system, the
to operate the system, including the fuel and ash gas temperature was maintained above the
handling.

2.2. Furl characteristics

Table 2. Typical proximate and ultimate analyses (wt”& db)
The gasification system was successfully of sugarcane leaves and bagasse” “I
tested on sugarcane leaves and bagasse, sweet
Leaves Ba.tuasse

Proximate analysis
Table I. Physical properties of sugarcane leaves (chopped) Fixed carbon 14.9 20.1
and bagasse’ Volatile matter 17.4 75.X
Ash 7.7 4.2
Chopped Bagasse
Higher heating value (MJ kg ‘) 17.43 IX.1 I
leaves Bagasse
Ultimate analysis
Particle size (cm) I- 10 c5 C 39.8 44.1
Bulk density (kg m ’db) 2540” 50-75 H 5.5 5.26
Moisture content (wt% wet) < I5 l&l5 0 46.8 44.4
N 0.19
,‘For loose leaves.
144 R. JORAPUR and A. K. RAJVANSHI

Table 3. Gasifier performance data at NARI user-industry, engaged in the manufacture of

Operating time (h) 700 speciality ceramic refractories. The gasifier was
Fuel consumption (kg h-’ db) 40-100
retrofitted to an LDO-fired ceramic baking
Gas characteristics
Flow rate (m’h-’ s.t.p.) 80-225 furnace in this factory. This was a tunnel
Higher heating value (MJ m-’ s.t.p.) 3.56-4.82 furnace, 5 m long, 3 m wide and 3.5 m high. The
Char characteristics
ceramic products were loaded on trolleys each
Yield (wt%) _ 24
Higher heating value (MJ kg-‘) 18.9-23 carrying 200-550 kg depending on the nature of
Ash (wt%) 35-45 the product. The product had to be dried from
Process parameters”
w 35wt% moisture content to < lwt% (wet
Gas outlet temperature (‘C) 45tx-550
Gas temperature at burner inlet (“C) 3OWO basis). At any given time, seven trolleys were
Gasifier performance (MJ h-‘) inside the furnace. Every hour, one trolley was
Total thermal output 468- 1620
removed from the furnace and one fresh trolley
Energy content of gas 288-1080
Energy content of char 180-540 entered it. The furnace was operated at a fairly
“In steady state.
constant oil firing rate. Thus, when the furnace
doors were opened to remove and add a trolley
each hour, the temperature of the furnace
condensation temperature of the tar compounds tended to drop. Once the furnace doors were
right up to the burner. Thus there was no closed, the temperature then tended to rise. This
condensation of tars, and so this problem did frequent variation in the furnace operating
not arise, due to the use of a hot gas cleaning temperature is seen in Fig. 4. The major
system. The blower impeller was also free from requirement of the process was that the
any deposits or scale. Thus a major source of temperature inside the furnace should be
downtime in most gasification systems, namely maintained in the range 15&2OO”C at all times.
that of choking of pipes/equipment with tars Since the furnace loading varied depending on
and particulate matter,” appeared to be the product mix, the oil firing rate had to be
successfully overcome by using a hot gas adjusted intermittently to maintain the furnace
cleaning system. temperature within those limits.
Tests with different moisture contents of the Only a part of the flue gases from the tunnel
fuel indicated that excellent performance was furnace was vented to the atmosphere through
possible if the moisture content was < 15wt% a chimney. The rest of the gases were mixed with
(wet basis). A pilot flame to sustain gas the hot combustion gases and recirculated inside
combustion was found to be necessary for the furnace. The combustion chamber was 3 m
moisture levels of 20-25wt%. However, com- long and 2 m wide and was designed to burn
bustible gas was not formed at all if the moisture 20 L h-’ (720 MJ h-‘) of light diesel oil (LDO).
content exceeded 25wt% (wet basis). The producer gas burner was inserted adjacent
This system was then subjected to more to the LDO burner in the combustion chamber.
rigorous testing by installing it in an actual This entailed minimal changes in the chamber

Furnace operation on
?? LDO

b/
150 1 1 1 1 I I I I 1 I I I 1 1 I I I I I I I I I
0 15 30 45 60 75 90 105 I20 135 150 165 I80 195 210 225240255 270 285 300 315 330 345 : 0
Time (minutes)
Fig. 4. Furnace temperature when operating on LDO and on the gasification system
 Sugarcane leaf-bagasse gasifiers for industrial heating applications 145

Table 4. Gasifier performance during field testing Table 6. Energy cost delivered to furnace’

Gasifier output (MJ h-‘) 396684 Fixed cost components

Biomass consumption rate (kg h-’ db) 55-12 (Rs year ‘)
Gas flow rate (m’h ’s.t.p.) 100~170 Depreciation ll0000
Gas outlet temperature (‘C) 4O(f600 Interest 53 750
Burner inlet temperature ( C) 200-300 Maintenance 22 000
Wages + salaries l10000
Electricity II2500
Total 408 250

construction and at the same time allowed the Gasifier output (MJ h ‘)

furnace to be operated on LDO alone, on the 615 1080

gasifier alone, or on any combination of Energy cost (Rs GJ ‘)
the two. This was essential to maintain the Fixed cost 79.6 50.4
Fuel costh 118.0 118.0
quality of the product and to prevent disruption total 197.6 168.4
of the production schedule if there was some Light diesel oil (LDO)
problem with the gasifier. cost (Rs GJ -‘) 280.3

During these trials, the furnace was operated ,‘I995 prices; US$ I = Rs 31.
exclusively on the gasifier in most cases. hRs 1000 t ‘.
‘Rs 7.5 L ‘.
Occasionally, both oil and gas firing was carried
out simultaneously. The results were as follows:
that the gasifier was operated at a maximum of
1. The quality of the baking and the colour
only 684 MJ h-‘, whereas the rated capacity of
of the refractory product using the gasifier were
the system was 1080 MJ h-’ (Table 3).
found to be as good as, if not better than, those
The biomass consumption rate during these
obtained using LDO. Moreover, there was no
trials normally varied between 55 and 72 kg h-’
deposition of particulate matter either on the
(dry) depending on the furnace loading. At full
product itself or on the furnace walls. This
blast, the corresponding LDO consumption was
meant that the level of particulates in the gas
18.75 L h-‘. So the economics of the system
was quite acceptable for applications involving
were evaluated by using an equivalance of 72 kg
drying and baking of ceramic products, or for
(dry) biomass to every 18.75 L of LDO, or
generating steam in boilers.
3.84 kg (dry) biomass to 1 L of LDO.
2. The sizing of the gasifier reactor was also
The economic analysis of the system was
quite satisfactory. The temperature profile of
evaluated both at its rated capacity of
the furnace could be easily maintained on the
1080 MJ h-’ and at the output of 675 MJ h-’
gasifier alone, as is seen in Fig. 4. The gas flow
which was usually required during the field tests.
rate had to be adjusted intermittently to
The data used for this analysis are given in
maintain the temperature at 150-200°C. The
Table 5.
response of the gasifier to a change in the gas
Table 6 shows the energy cost for a net landed
flow rate was quite satisfactory in the range
biomass cost of Rs 1000 t-’ (dry). The costing
tested (IO&170 m’h-’ at s.t.p.). Its response was
for other biomass prices is given in Fig. 5.
almost instantaneous, and the gas was not
Figure 5 shows that the system is economi-
extinguished even momentarily. Further, there
cally attractive if the biomass cost (dried, sized
was no change in the furnace operating routine.
and landed cost at the gasifier site) is less than
Data were collected on the gasifier operating Rs 1100 tt’ (dry) when the LDO price is
parameters, as shown in Table 4. It is evident Rs 7.5 L-’ and when the gasifier system is

Table 5. Economics of the NARI gasification system”

Cost of gasifier system Rs 525 OOOh
Civil construction cost Rs 25 000
intended operating rate 7500 h year-’
Depreciation 20% p.a. by straight-line method
Interest 18% p.a. annualised over 5 years
Wages + salaries 2 persons/shift x 3 shifts/day x 365 days/year x Rs 50/(personday)
Maintenance cost 20% of capital cost spread over 5 years
Electricity cost 6 kW x Rs 2.5 kWhh
Biomass consumption 118 kg GJJ’
,‘Gasifier rating 1080 MJ h-‘.
h1995 prices; US.% I = Rs 31.
146 R. JORAPURand A. K. RAJVANSHI

900 1000 I100 1200 1300

Biomass cost (Rs/T (dry))
Fig. 5. Economics of the gasification system.

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