ENERGY BALANCE STUDY ON

GASIFCATION AND
SYN GAS UTILIZATION

By
Saravana Bharathy R
Sanjay Kumar,
M.Tech (ES - IV),
Professor,

Guided by,
Mr. G.
Assistant
Department of
Chemical

ABSTRACT

The project is involved in having the energy balance on the pilot

scale gasification plant for various downstream utilization options.

The products from gasification is used to generate heat and power
through gas turbine and turbine with generating heat for the
gasification process to take place in the gasifier which requires
steam at an pressure range of 5 bar @ 350C.
The whole process has been simulated on the ASPEN Plus
simulator. In this flowsheet of various applications has been created

and has been simulated by giving the boundary conditions of the

gasifier. Various utilization conditons like CHP(Contionous Heat
and Power), With Gas Turbine, With Gas Engine, With Drying of

BACKGROUND
Gasification is an technique which is under development
for the improvement of energy conversion and also for

direct utilization applications. Since the gas has varied

composition of components, it can be utilised for variety
of

applications.

This

includes

the

production

of

hydrogen, natural gas, fuel cell power generation and

power generation through various modes.
In this project, there is an major concentration made on
the power generation applications through gas engine,
gas turbine, fuel cell and having an CHP profile.

OBJECTIVE

Investigation of energy balance of a gasifier for

various downstream gas utilization options in
ASPEN Plus
Thermodynamic optimization of Gasification
process including usage of products
Checking the balance of various applications and
Thermodynamic optimization of the energy
conversion system.

Methodology

The properties are been listed for the syngas

receiving end and for the process equipments and for
the final gas process.
The flow sheet has been made for the requirement of
the application and enter the boundary condition on to
it.
If required enter the calculator blocks for having the
different calculation on the system. This will calculate
the particular formula we entered into it.
Then the simulation will be done and the results has
been generated.
The calculator block has been entered through the
FORTRAN codes or through Excel.

ASPEN PLUS
ASPEN PLUS simulator provides an opportunity to check the
feasibility of a process, to study and investigate the effect of

various operating parameters on various reactions. It is a

strong tool for simulation studies and helps in analyzing the
outcome of a process.

Kinetic model: here we can simulate the reaction conditions

at different times and sites which will make it suitable for
reactor amplification design and operation

parameters

optimization.
Equilibrium model: it predicts only end reaction product
distribution but gives no idea about the instantaneous product

Downstream applications
Continuous Heat and Power
Solid Oxide fuel cell application
Gas turbine application
Gas turbine application with drying of
feed
Gas Engine application

Process model

Process model Contd.,

SYNGAS COMPOSITION
Component

kmol/hr

Mole % wet basis

Molecular Wt

mass flow rate

(kg/h)

H2

1.135

18.22210092

2.27

CO

1.0128

16.26021481

28

28.3584

CO2

1.1848

19.0216257

44

52.1312

CH4

1.0961

17.59757253

16

17.5376

H2O

1.3277

21.3158444

18

23.8986

Char

0.4723

7.582641643

16.06425703

6.2287

7.58714859
131.782949

Continuous Heat and Power

In this flow sheet the production of power
is an major concern other than for the heat
for the feed drying. The assumption has
been made for the gas turbine is operating
the system and the final exhaust has been
not on the dew point temperature of Flue
gas.

Flow sheet

Flow sheet answers

Stream/Properties
Temperature K
Pressure atm
Vapor Frac
Mole Flow kmol/hr
Mass Flow kg/hr
Enthalpy Watt

AIR

COMPAIR

SYNGAS

FINALGAS

EXHAUST

FLUEGAS

HM1

HM2

WATER

STEAM

EXHAUWAT

573

1056.4

673.1

1473.2

773.1

1173.2

800.8

684.7

333.1

773.1

313.1

4.935

44.412

34.542

4.935

14.804

14.804

10

10

0.888

17.331

17.331

5.8

22.049

22.049

1.633

23.682

23.682

1.665

1.665

1.665

500

500

125

625

625

50

675

675

30

30

30

39210.6

113615

-251730

-415190

-580710

-13332.6

-594050

-621030

-130990

-104010

-131660

1.148

1.017

1.188

3.313

3.313

0.245

3.558

3.558

1.108

13.691

13.691

13.691

13.691

1.307

14.998

14.998

3.639

3.639

0.341

0.341

0.082

0.423

0.423

1.339

4.703

4.703

4.703

4.703

1.665

1.665

1.665

Mole Flow kmol/hr

H2
CO
CO2
CH4
N2
O2
AIR
H2O

Work
4

W3

78.32

-245.39

3.33

Discussion
Since the heat and power is the major concern the loss
will be in the form of waste heat as the process has
loss in the losing of heat in the system. This is because
of heating the liquid in the system itself causes a major
heat loss and the process must leads to decrease of
overall efficiency.

Solid Oxide Fuel cell

The SOFC is a highly efficient energy conversion
device due to the fact that it converts the chemical
energy contained in a fuel gas directly to electrical
energy by means of electrochemical reactions. SOFCs
can utilise a wide spectrum of fuels due to their high
operating temperatures.
This will use in the supplementary power
production and utilize the energy in the proper and
easier way.

Flow sheet

SYNGAS

COMPG HEATGA TOPREFO TOANOD

AS
S
R
E

AIR

COMPA HEATAI HX2CAT CAT2A CAT2FI CAT2A ANO2SPL SPL2CO COMB2 FINALGA
IR
R
H
NOD
NA
NOD
I
MB
HX
S

Substream:
MIXED
Mole Flow
kmol/hr
H2

1.10

1.10

1.10

2.12

3.86

0.00

0.00

0.00

0.00

0.00

0.00

0.00

2.05

1.02

0.00

0.00

CO

0.97

0.97

0.97

1.89

1.84

0.00

0.00

0.00

0.00

0.00

0.00

0.00

1.84

0.92

0.00

0.00

CO2

1.13

1.13

1.13

2.74

3.22

0.00

0.00

0.00

0.00

0.00

0.00

0.00

3.22

1.61

3.16

3.16

CH4

1.06

1.06

1.06

1.69

1.27

0.00

0.00

0.00

0.00

0.00

0.00

0.00

1.27

0.63

0.00

0.00

H2O

1.28

1.28

1.28

3.48

2.58

0.00

0.00

0.00

0.00

0.00

0.00

0.00

4.39

2.20

4.49

4.49

N2

0.45

0.45

0.45

0.90

0.90

20.54

20.54

20.54

20.54

0.00

20.54

0.00

0.90

0.45

20.99

20.99

O2

0.00

0.00

0.00

0.00

0.00

5.46

5.46

5.46

5.46

0.91

4.55

0.91

0.00

0.00

2.31

2.31

AIR

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

5.99

5.99

5.99

12.83

13.67

26.00

26.00

26.00

26.00

0.91

25.09

0.91

13.67

6.84

30.95

30.95

293.03

293.03 750.00 750.00 750.00 750.00 29.03 720.97 29.03

322.06

161.03 882.00

882.00

Total Flow
kmol/hr
Total Flow
kg/hr

132.00 132.00 132.00

Total Flow
l/min

1862.42 527.10 483.15 19301.10 1481.70 6792.29 2160.17 1616.61 2582.51 90.12 2492.39 90.12 1307.38 653.69 3144.88 2340.67

Temperature K 673.15 952.57 873.15 1123.15 1173.15 573.15 911.40 673.15 1075.35

1075.3
1075.3
5 1075.35 5
1173.15 1173.15 1173.15 873.15

Pressure atm

2.96

14.80

14.80

1.02

14.80

16.78

15.00

14.80

14.80

14.80

14.80

14.80

16.78

16.78

15.79

15.79

Vapor Frac

1.00

1.00

1.00

1.00

1.00

1.00

1.00

1.00

1.00

1.00

1.00

1.00

1.00

1.00

1.00

1.00

Liquid Frac

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

Solid Frac

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

Enthalpy
cal/mol

34300.4 31477.2 32311.3

37516.3
6051.4
6051.4
37516.3 10861.2
3
1
0
34114.82 30085.11
7
4491.85 2679.35 5788.26 6 5778.74 6 37516.37
7
9
13472.38

Enthalpy
cal/gm

1556.45 1428.35 1466.19 -1493.18 -1403.67 1592.61 155.69 92.87 200.63 189.12 201.09 189.12 -1592.61 1592.61 -381.16 -472.79

Enthalpy
cal/sec

57070.0 52372.6 53760.4 121540.0 114250.0 71237.8 32436.3 19348.0 41797.9 1524.9 40273.0 1524.9 142480.0 71237.8 93384.1 115830.0
0
6
4
0
0
3
3
4
4
4
0
4
0
3
8
0

Entropy
cal/mol-K

6.22

6.52

5.61

13.45

9.52

8.14

3.74

1.46

5.07

4.43

4.98

4.43

8.14

8.14

5.87

3.30

Entropy
cal/gm-K

0.28

0.30

0.25

0.59

0.44

0.35

0.13

0.05

0.18

0.14

0.17

0.14

0.35

0.35

0.21

0.12

Density
mol/cc

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

Density
gm/cc

0.00

0.00

0.00

0.00

0.00

0.00

0.01

0.01

0.00

0.01

0.00

0.01

0.00

0.00

0.00

0.01

Average MW

22.04

22.04

22.04

22.85

21.43

23.56

28.85

28.85

28.85

32.00

28.74

32.00

23.56

23.56

28.50

28.50

Liq Vol 60F

l/min

4.59

4.59

4.59

9.39

10.68

4.80

23.20

23.20

23.20

0.81

22.40

0.81

9.60

4.80

24.97

24.97

Voltage Calculation result

Voltage Calculation
Gibbs free energy formation
of gas stream J/mol
Faraday's constant

187898

400

Tout

900

650

molar gas constant

8.314

P H2 (bar)

0.778

P O2 (bar)

2.331

P O2^o.5

1.5267613

P H2O (bar)

8.778E-09

Ohmic loss in Cathode =

cat*cat/Aact

2.873E-06

96845

Tin

Tavg

Ohmic loss calculation

Ohmic loss in anode =
an*an/Aact

4.73

ln((PH2*Po2^o.5)/PH20)

-1.381805

RgTavg/2F

0.0143804

Voltage

0.9502256

Current

298732.93

Power

283.86368

Ohmic loss in electrode =

ele*ele/Aact
Ohmic loss in anode =
int*int/Aact
Total ohmic loss V

Activation loss
Specific current Density J
(A/m^2)
For Anode
(1/Ract a) = (2F/Rg.
Top)*Ka*(PH2/Po)^m*e^(Ea/RgTop)

7.709E-05
0.000225
0.0911039

Concentration loss

Loss at cathode = Ract a * J

(1/Ran a) = (4F/Rg.
Top)*Kc*(PO2/Po)^m*e^(Ec/RgTop)
Loss at cathode = Ran a * J

Loss in cathode =
(RT/2F)*ln(1-Uf*Ua)

-0.003571

Total voltage loss by activation

Loss in anode =
(RT/2F)*ln(1-Uf )
Total loss

-0.073289
-0.07686

Total Active voltage

Total power

1500

2.44E-05
0.036

9.79E-05
0.146
0.182
0.7539816
225.23913

Discussion
The SOFC power production is majorly depends on the
temperature and the amount of oxygen inlet into the
system. The cathode separation plays an important role
and it shows the amount of oxygen inlet into the anode
and also for the reactor for final combustion. The half
reaction produces an voltage corresponding to the
reactor temperature and also the concentration of
oxygen inlet to the reactor.
The voltage and current has been calculated separately
in MS Excel to find the precise amount of concentration

of oxygen inlet to system for the production of power in

Combustion Chamber and Gas

Turbine
In this cycle the product from gasification is been send
into the gas turbine and the power has been produced
through the gas turbine and also through the steam
turbine which utilizes the waste heat from the gas
turbine to produce power.
In this two systems has been devised (i.e., with and
without drying). The system devised has an drying
setup which is used to reduce the moisture content of
the feed onto the system. The hot feed will re circulated for gasification to produce syngas. This feed
has an lesser moisture compared to the feed.

CCGT without drying system Flue

gas path

CCGT without drying system

Water column path

Property/Strea
m

COMP SYNG CCEXH FLUEG

AIR AIR
AS
AUS
AS

GTEX
SH2H HRSG ECO2P TOEXH TOPRE TOECO ECO2H HRSG
STEXH
TOGT HA TWC RSG 2ECO RE
AUS HEA NOM RSG 2SH TOST AUS

Temperature K

573.1 1066. 673.1 1223.2 1223. 1223. 1573. 954.2 1173. 1156. 961.7 917.8
673.1 773.1 454.9 303.1
0
90
0
0
20
20
20
0
20
10
0
0 892.80 303.10 373.10 473.10 0
0
0
0

Pressure atm

1.78 15.99 9.87 39.48 9.87 34.54 44.41 1.05 39.48 39.48 39.48 39.48 39.48 40.00

40.00

40.00 40.00 40.00 1.00 1.00

Vapor Frac

1.00 1.00 1.00

1.00

0.00

0.00

0.00

1.00 1.00 1.00 0.00

Mole Flow
kmol/hr

17.33 17.33 5.89 22.20 0.02 22.22 22.22 22.22 22.22 22.22 22.22 22.22 22.22

3.89

3.89

3.89

3.89 3.89 3.89 3.89

Mass Flow
kg/hr

500.0 500.0 132.0

632.5 632.5 632.5 632.5 632.5 632.5 632.5
0
0
0 632.00 0.57
7
7
7
7
7
7
7 632.57 70.00

70.00

70.00 70.00 70.00 70.00 70.00

Volume Flow
l/min

7646. 1581. 549.6

1076. 1076. 27549 903.0 889.9 740.3 706.5
98
68
1 940.80 3.08 08
44
.23
8
5
1
5 687.27 1.18

1.27

1.45 89.43

Enthalpy
MMkcal/hr

0.03 0.10 -0.20 -0.37

-0.26

-0.25 -0.21 -0.21 -0.22 -0.27

1.00

1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00

0.00 -0.37 -0.30 -0.43 -0.38 -0.39 -0.43 -0.43 -0.44

-0.27

102.7 2417.
1
48 1.18

Mole Flow
kmol/hr

H2

0.00 0.00 1.08

0.00

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

0.00

0.00

0.00

0.00

0.00 0.00 0.00 0.00

CO

0.00 0.00 0.96

0.00

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

0.00

0.00

0.00

0.00

0.00 0.00 0.00 0.00

CO2

0.00 0.00 1.13

3.10

0.01 3.11 3.11 3.11 3.11 3.11 3.11 3.11

3.11

0.00

0.00

0.00

0.00 0.00 0.00 0.00

CH4

0.00 0.00 1.02

0.00

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

0.00

0.00

0.00

0.00

0.00 0.00 0.00 0.00

H2O

0.00 0.00 1.26

4.37

0.00 4.38 4.38 4.38 4.38 4.38 4.38 4.38

4.38

3.89

3.89

3.89

3.89 3.89 3.89 3.89

N2

13.69 13.69 0.00 13.69 0.01 13.70 13.70 13.70 13.70 13.70 13.70 13.70 13.70

0.00

0.00

0.00

0.00 0.00 0.00 0.00

O2

3.64 3.64 0.45

1.04

0.00 1.04 1.04 1.04 1.04 1.04 1.04 1.04

1.04

0.00

0.00

0.00

0.00 0.00 0.00 0.00

AIR

0.00 0.00 0.00

0.00

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

0.00

0.00

0.00

0.00

0.00 0.00 0.00 0.00

Discussion
The CCGT system produces an higher power and also
relatively it has higher efficiency than the other systems,
due to the using of steam turbine attached into the
system. The major concern is that more than (1/3)rd of
the power is consuming in the compressor. This has to
be reduced and also the power from the Gas turbine is
related with the temperature and pressure of the gas
inlet into the turbine. If the temperature increases the
power produced is also get increased.
The heat loss comparatively less as the drying of the
feed is not included in the system.

CCGT with drying system Flue

gas path

CCGT with drying system Flue

gas path

Work Need to Finish

Make a flow sheet of Gas Engine in ASPEN Plus for

the simulation of power production.
Analyze, Simulate and produce the results of power
production and energy production in different
operating conditions.
Produce an thermodynamic optimized system and
produce the results in an common scale.

Thank you!!!!