1

Troubles with Gasification System

Gasification is quite complex and sensitive
process

There exists high level of disagreement

about gasification among engineers,
researchers, and manufacturers

Many manufacturers claim that their unit can

be operated on all kinds of biomass

But it is quite questionable fact as physical

2
and chemical properties varies fuel to fuel
Troubles with Biomass Gasification system
Getting the producer gas is not difficult, but obtaining
the gas in the proper state is the challenging task

Gasoline and diesel have quite homogenous property

The physical and chemical properties of producer gas

such as energy content, gas composition and
impurities vary from time to time

All the gasifiers have fairly strict requirements for fuel

size, moisture and ash content

Inadequate fuel preparation is an important cause of

technical problems with gasifiers 3
Troubles with Biomass Gasification system

Gasifier is too often thought of as simple device that

can generate a combustible gas from any biomass
fuel

A hundred years of research has clearly shown that

key to successful gasification is gasifier specifically
designed for a particular type of fuel

Those interested in this technology must remember

that it requires hard work and tolerance

Although technology is inconvenient, it is economical

at many places and may lead to self-reliance in fuel
crisis 4
Troubles with Biomass Gasification system

Operation of diesel or gasoline engine is simple

Engine starts immediately and there is no

trouble within the run

Handling of liquid fuel is also easy task

Anybody expecting something similar will be

disappointed with operation of gasifier
5
Troubles with Biomass Gasification system
It requires at least half an hour or more to start
the system

Fuel is bulky and frequent refueling is often

required for continuous running of the system

Handling residues such as ash, tarry

condensates is time consuming and dirty work

Driving with producer gas fueled vehicles

requires much more and frequent attention than
6
gasoline or diesel fueled vehicles
7
 Small-Modular Gasification
Gasification-based small modular biomass systems are emerging as a
promising technology to supply electricity and heat to rural areas,
businesses, and the billions of people who live without power worldwide

Biomass Program support through subcontracted efforts with private sector

companies over the past several years, has advanced several versions of
the technology to the point where they are now approaching
commercialization

By adopting a standardized modular design, these 5 kW-to-5 MW systems

are expected to lend themselves to high volume manufacturing techniques
to bring them on a competitive level with large stand-alone plants

Using locally available biomass fuels such as wood, crop waste, animal
manures, and landfill gas, small modular systems can be brought to the
source of the fuel rather than incurring transportation costs to bring biomass
fuels to a large centrally located plant

Small modular biomass systems also fulfill the great market potential for
distributed, on-site, electric power and heat generation throughout the world
8
 Small-Modular Gasification
Small modular biomass systems typically convert a
solid biomass fuel into a gaseous fuel through a
process called gasification

The resulting gas, comprised primarily of carbon

monoxide and hydrogen, is then cleaned before use in
gas turbine or internal combustion engine connected
to an electrical generator

Waste heat from the turbine or engine can also be

captured and directed to useful applications

Small modular systems lend themselves to such

combined heat and power operations much better
9
than large central facilities
 Status of the technology
The gasification of biomass and biomass waste
in supercritical water is a rather novel process

Significant R&D work will be required prior to

implementation and commercialization

Currently, the focus is on experimental

research in a continuous flow unit (10 - 30 L/h)

10
11
Benefits of Small Modular Systems

Small Modular biomass systems offer many benefits

to potential customers

They have minimal environmental impact when

compared to other existing technologies using coal or
biomass as the fuel

On the one hand, economics can be attractive when

owners connect the unit to a power grid that will buy
unused power

On the other, small modular systems can electrify

isolated areas for which the cost of connection to12the
grid is prohibitive
Benefits of Small Modular Systems
Another economic benefit may be realized if the customer has a
biomass waste stream that can be converted into a source of
energy rather than being an economic burden

The flexibility to use more than one fuel also appeals to many
users

Modern microprocessor control has been coupled to

gasification technology to result in systems requiring minimal
operator attention

And, in off-grid locations small modular biomass systems offer

the potential for lights, refrigeration, heat and power to enable
small cottage industries to become economically viable
13
14
Description of technology and features
Able to directly treat green wood with moisture content of 35-
50% without using a drying process

High heat-use efficiency thanks to heat exchange within the

gasifier ( cooling gas efficiency, including tar, is 86-88%)

Power generation efficiency is approx. 30%

Quick turn-down to 10%, for greater operational flexibility Fully

automated operation, requiring only a small maintenance staff

Waste tar water is cleaned with self-generated heat and can be

released to public sewers

Ash has little residual carbon and no dioxin 15

Model of a typical biomass gasification plant

16
First cost (lower the better)

Reliable continuous operation

Minimal maintenance cost and down time

Faster return on investment

Power levels of a few kWe to a few MWe

Look for approaches to obtain high gasification

efficiency 17
Carbon Cycle of Bioenergy
CO2
CO2
Bioenergy
Plant

Biomass
products

Biofuels

18
 Biomass Fuels
Characteristics variations
as a fuel:
- Large number of biomasses
available with various
Bagasse properties
- Water content 10 - 65%
- Net heat value 518 MJ/kg
- Chemistry variations

Rice - Bulk density 60350 kg/m3

- Particle size: powder - piece
Wood chips husk of log
Bark
Saw dust
Canary Grass Challenge for handling
and combustion
engineering 19
Bubbling Fluidized Boilers (BFB)

20
Circulation Fluidized Boilers (CFB)

21
22
23
 Rice husk is the most abundant agricultural residue in the world

Limitations
The components of the husk which affect its energy value are:
ash content, volatile matter and fixed carbon

The quantities of these components in the husks are achieved

by the proximate analysis method

This method is capable of giving approximate values of the

components

The energy content of rice husks is rather low

This is due to the high fixed carbon values of the product

This implies that large quantities of the carbon remain 24

ungasified leading to the production of large quantities of ash
 Limitations
The resulting ash requires constant removal from the
gasifier bed and this slows the working process

Furthermore, the ash contains alkaline oxides of

potassium and sodium that change their physical
forms from the solid state during the pyrolysis of the
husks

The liquefied oxides present removal problems to the

operator

Gasification is therefore an ideal utilisation pattern

despite its operational limitations
25
 Current Pattern of Energy Consumption
Current world energy consumption is dominated by fossil fuels and is rising

Primary Final

World energy consumption in 2001

Note: Other includes geothermal, solar, wind etc. 26
Current Pattern of Energy Consumption contd.
Inadequate modern energy services in developing
countries.
Current pattern of world energy consumption is not
sustainable:
- Environmental implications: Global warming and
others
- Depletion of the reserves of fossil fuels

Importance of Biomass Energy

Biomass is the 4th largest source of energy
worldwide and account for about 35% of
consumption in developing countries currently 27
28
29
30
Energy consumption in most developing countries is rising
rapidly

Because of environmental considerations, the share of

renewable energy in general and biomass in particular, in the
total energy supply is expected to rise in the future

There is a need to assess the full potential of biomass

(plantation-based and others) in different countries

Biomass has an advantage of high employment potential per

unit of energy output

Many modern BETs are fully or nearly mature at Present

There is a need to assess/monitor these BETs

Barriers to transfer/diffusion of promising BETs should31 be

identified and ranked for removal
 Carbon Emissions

The sectoral share of carbon

emission is:

Industrial (55.0%)

Transportation (22.2%)

Residential (16.1%) and

Commercial (6.7%)
32
 The Status

Installed Capacity > 120 GW

Gross Generation: 620 billion kWh

Per Capita Consumption ~ 600 kWh

Coal dominant energy source (58%)

Ministry of Power, Government of India

33
 Fuel Supply: Options for Future
Coal Fuel Present In 2015
Conventional Coal 67,166 MW ?
Gasification
Natural Gas Gas 11,840 MW ?
Hydro Hydro 30,135 MW ?
Nuclear Nuclear 2,720 MW ?
PHWR + FB + AHWR
PLWR Wind 2,488 MW ?
Wind Biomass 1,000 MW ?
On-shore
Off-shore
Solar - ?
Biomass TOTAL 115,035 MW 250,000 MW
Solar
Photo voltaic
Concentrating Solar Power

34
 King Coal !
Reserves
Proven 91 billion Tons
Indicated 116 billion Tons
Inferred 37 billion Tons
TOTAL 245 billion Tons

Coal reserves: > 250 years

at present levels of consumption

Concentrated in Eastern India

35
 Indias CO2 Emissions
Indias fossil based CO2 emissions in
2003: 35%
Coal 666 MMT US
30%
Petroleum 305 MMT
Natural Gas 53 MMT

Share of Global CO2 Emissions (%)

25%
Western Europe
20%
Indias CO2 emissions rapidly growing
Trebled during 1981-2001 15%
China
Share of global emissions 10%
India China Total
India
5%
1980 1.64% 7.83% 9.47%
2003 5.60% 19.34% 24.93% 0%
1980 1985 1990 1995 2000 2005

EIA, US Department of Energy

India and China presently not subject to

mandatory cuts in CO2
However future may not be so 36
 Biomass
India predominantly agricultural
country.
Annual production of agro-forest Feedstock Examples Potential Installed
and processing residues: 350 Agro-forest Wood 17,000 MW 50 MW
million tons residues chips,
mulberry,
Power generation potential > coconut
shells
22,000 MW
Processing Rice husk, 5,000 MW 1000 MW
Advantages: residues sugarcane
Decentralized generation: close to bagasse

rural load centers.

Technology reasonably well
developed
Environmentally friendly: No net
CO2 emissions

37
 Biomass Conversion Technologies
Gasifier-reciprocating engine 50 kW biomass gasifier power plant in Karnataka
Power plants of 5 kW 100 kW
possible
Diesel engine needs ~ 15%-20% for
ignition
Cost of electricity is high
Gas engine can operate on 100%
syngas
Overall efficiency ~ 20%
Largest gasifier 100 kW

Fluidized bed combustion boilers

Rice husk and bagasse
25%-30%
Power plants of 5 MW 35 MW operating in
various sugar mills
Producing electricity is sweeter than sugar !!

38
 What If.
India & China Were Developedby 2013?
Present Electricity Per Capita (kWh) Global Carbon Emissions (Million Tons per Year)

US > 14,000
India 600
China 1300

Target: 14,000 kWh by 2013

Expected Carbon Emission:
14,400 Million Tons (2.5 times
present global emissions !!)
CO2 concentration > 400 ppm
Temperature rise > 0.5 C

(Calculations Based on Data in Climate Change 2001, IPCC)

39
Biomass energy is only renewable and direct
deposit energy. It is the fourth energy in all
resource, reached 14% of total world energy
consumption.

Biomass energy reached 35% in developing

countries. The consumption of biomass
energy will reach 38% of consumption of all
world energy in 2050.

40
 Bio mass
Good response from captive
power producers using rice husk
as feed stock

Only one manufacturer of gasifier

units in the state.

State has more than 1200 rice

mills in operation

Central ministry is providing

attractive subsidies.

Income tax benefit, as

depreciation, is available.

Investment opportunities are to

the tune of Rs 5600 Crs.

41
42
43
 Bio mass
Biomass is a primary source of energy having undebateable potential of
supplementing the energy needs of the country in a foreseeable future

It is a versatile resource that can be utilized as an alternate source of energy

for variety of applications:

power generation,
thermal applications and
also as feed stock for different industries

Gasification is an important intermediate step towards utilisation of Biomass

in most applications

Gasification technology and gasifier systems assume immense importance in

this context

Gasifier systems are Biomass specific as well as application specific

Quality assurance and standardization of such systems is an important

44 but
difficult task
 Bio mass
Ever-increasing consumption rates of fossils fuels and rapid depletion of the
known reserves are a matter of serious concern, the world over

Conservation of conventional fuels through utilisation of renewable energy

sources is an effective approach towards alleviating these constraints

Domestic and abundant availability and non-depletable nature are essential

attributes of a resource for it to qualify as a renewable source of energy

Biomass stands out as a promising resource in this context, more so for

tropical countries, having plentiful sunshine and rains

The main areas where biomass can play an important role are shaft power
applications through I.C. Engines and Gas Turbines, thermal applications
like boilers, furnaces, kilns etc. and production of chemicals and fuels

In most applications, conversion to a gaseous or liquid form is the essential

intermediate step towards utilisation of biomass

In this context, thermo chemical gasification of biomass emerges 45

as an
important aspect of biomass utilisation
 Bio mass
Energy security is a fast growing need, both in industrial and rural
India

One means of meeting this growing need in an inexpensive and

clean manner is through the increasing use of renewable
biomass through the process of Biomass gasification

This, is the conversion of solid biomass into a combustible gas

mixture called Producer-gas through a partial combustion route
under substoichoimetric conditions

Carbon monoxide and Hydrogen (which are toxic/lethal gases)

are the two main combustible components as a result of which
there is a need for care in designing and operating such systems

Conversion of biomass to a combustible gas mixture removes

most of the conventional problems associated with the use of
solid biomass fuels in combustion 46
 Bio mass
This process can be employed from a scale of 3-5kW up to
several megawatts

Hence is ideally suited for decentralized applications whether

they are for shaft power, electricity or thermal energy, where
most of the current applications exist

When used to generate power, the raw and hot producer gas
needs to be cooled and cleaned, before used in reciprocating
engines/gas turbines

With the large variation in the physical and chemical

characteristics of the wide variety of biomass available in India, it
is important to understand that gasifier systems are not only
application specific but are also biomass specific

There is, therefore, a need to characterize the intended fuel(s)

so that the end-users can satisfactorily meet the requirements
47 in
terms of the raw material (biomass) used in the gasifier
48
49
50
51
52
 Introduction
Generally, biomass gasification is a thermal
conversion technology where a solid fuel is converted
into a combustible gas

A limited supply of oxygen, air, steam or a combination

serves as the oxidizing agent

The product gas mainly consists of carbon monoxide,

carbon dioxide, hydrogen, methane, water, nitrogen,
but also contaminants like e.g. small char particles,
ash and tars

After cleaning the gas makes is suitable for boiler,

engine use, and turbine use to produce heat and
power (CHP) 53
 Process Chemistry
The substance of a solid fuel is usually composed of
the elements carbon, hydrogen and oxygen

In the gasifiers considered, the biomass is heated by

combustion

Four different processes can be distinguished in

gasification:
Drying
Pyrolysis
Oxidation and
54
Reduction
55
 The water gas shift reaction determines to a large extent the
final gas composition

The equilibrium constant (Kw) can be written as

Kw =/ [CO2] x [H2] / [CO] x [ [H2O]

In practice, the equilibrium composition of the gas will only be reached in
cases where the reaction rate and the time for reaction are sufficient

Below 700 the water-gas shift becomes so slow -without a

catalyst- that the equilibrium is said to be 'frozen

The gas composition then remains unchanged

Methane equilibrium will only be reached at very 56high

temperatures ( > 1200 C)
57
58
 For CHP applications in the small to medium size BTG applies the co-current fixed bed, and the
fluidized bed gasifier

In both cases air is used as the oxidant, and the gasifier is operated at ambient pressure

The next table presents typical gas composition data as obtained from wood and charcoal co-
current gasifiers operated on low to medium moisture content fuels (wood 20%, charcoal 7%)

Component Wood gas (vol%) Charcoal gas (vol%)

Nitrogen 50 54 55 65

Carbon monoxide 17 22 28 32

Carbon dioxide 9 15 13

Hydrogen 12 20 4 10

Methane 23 02

Heating value (MJ/Nm3) 5 - 5.9 4.5 - 5.6

For synthesis gas production BTG considers the pressurized, oxygen-blown entrained flow
gasifier fed with bio-oil (see bio-oil application )
59
60
 Principles of Gasification
Biomass is a natural substance, which accumulates solar energy as
chemical energy by the process of photosynthesis in the presence of sunlight

Biomass chiefly contains cellulose, hemi-cellulose and lignin, having an

average composition of C6H10O5, with slight variations

For the complete combustion of biomass the theoretically amount of air

required (defined as the stoichiometric quantity) is 6 to 6.5 kg of air per kg of
biomass and the end products are CO2 and H2O

In gasification, biomass is subjected to partial pyrolysis under sub-

stoichiometric conditions with the air quantity being limited to 1.5 - 1.8 kg of
air per kg of biomass

The resultant mixture of gases generated during the gasification process is

called producer gas, contains CO and H2 and is combustible

The raw producer gas also contains tar and particulate matter which have to
be removed as they are harmful to the engine 61
 Producer Gas Composition
The producer gas delivered from the gasifier
has the following average chemical
composition

CO : 20 + 2%
CH4 : 3 + 1%
H2 : 20 + 2%
CO2 : 12 + 1%
Rest : N2
The lower calorific value is about 4.5- 5.0 MJ/kg
(1000 - 1200 kcal/ m3) 62
63
 Producer gas Applications
Producer gas obtained by the process of gasification, can be employed in thermal
application or for mechanical / electrical power generation

Like any other gaseous fuel, producer gas affords much better control over power
levels when compared to solid fuel

This also paves the way for more efficient and cleaner operation

Thermal

For thermal applications, gasifiers are a good option as a gasifier can be retrofitted with
existing devices such as ovens, furnaces, boilers, etc.

Thermal energy of the order of 4.5 to 5.0 MJ is released by burning 1 m3 of producer

gas in the burner

Flame temperatures as high as 1200 C can be obtained by optimal air preheating and
pre-mixing of air with gas

Producer gas can thus replace fossil fuels in a wide range of devices. A few of the
devices which could be retrofitted with gasifiers are furnaces for melting non-ferrous
64 and
metals and for heat treatment, tea dryers, ceramic kilns, boilers for process steam
thermal fluid heaters
 Power Generation
A diesel engine can be operated on dual fuel mode
using producer gas. Diesel substitution of over 80% at
high loads and 70 - 80% under normal load variations
can be achieved

The mechanical energy thus derived can be used

either for driving water pumps for irrigation or for
coupling with an alternator for electrical power
generation

Alternatively, a gas engine can be operated with

producer gas on 100% gas mode with suitably
modified air / fuel mixing and control system
65
 Rice Hull or Husk Properties

Rice hulls are generated during the first stage of rice milling, when rough
rice or paddy rice is husked i.e. husk is separated from the rest of the grain

In general, 100 kg of paddy rice will generate 20 kg of hulls

Short grain varieties produce slightly more hull than medium or long grain
varieties

Moisture content of rice hull is around 10%; the equilibrium moisture content
is lower than that of paddy or rough rice

Bulk density of rice hulls is 100 to 150 kg/m3. If rice hulls are ground, bulk
density increases to 200 to 250 kg/m3

Rice hull contains 16 to 22% ash, and 90-96% of the ash is composed of
silica. Therefore, rice hull ash can be considered a slightly impure form of
silica

66
 Rice Hull or Husk Properties

The ash composition and structure give rice hulls an abrasive character

Metal surfaces in frequent contact with rice hulls will wear out and eventually
puncture
The calorific value of rice hull is 14-16 MJ/kg on a 10% moisture content
basis

In comparison, most dry woods contain 18-20 MJ/kg, and coal contains 25-
30 MJ/kg

The higher the ash content of rice hulls, the lower the calorific value

The main carbohydrate components of rice hulls are cellulose and lignin

Rice hulls contains only minor levels of potassium and chlorine, and
therefore ash melting temperatures of rice hull are much higher than those
of rice straw

Thus, you have less problems of "slag" (molten glass) deposits when
67 hull
rather then straw is used as a fuel.
 Rice Husks
Rice milling generates a by product know as husk

This surrounds the paddy grain

During milling of paddy about 78 % of weight is received as rice , broken rice

and bran

Rest 22 % of the weight of paddy is received as husk

This husk is used as fuel in the rice mills to generate steam for the parboiling
process

This husk contains about 75 % organic volatile matter and the balance 25 %
of the weight of this husk is converted into ash during the firing process , is
known as rice husk ash ( RHA )

This RHA in turn contains around 85 % - 90 % amorphous silica

So for every 1000 kg of paddy milled , about 220 kg ( 22 % ) of husk is

produced , and when this husk is burnt in the boilers , about 55 kg ( 25
68% )
of RHA is generated
 Rice Husks
India is a major rice producing country , and the husk
generated during milling is mostly used as a fuel in the
boilers for processing paddy , producing energy
through direct combustion and / or by gasification

About 20 million tones of RHA is produced annually

This RHA is a great environment threat causing

damage to the land and the surrounding area in which
it is dumped

Lots of ways are being thought of for disposing them

by making commercial use of this RHA 69
 BIOMASS PROPERTIES

Moisture content, calorific value and proximate

composition are the important biomass properties
from viewpoint of gasification process

Infrared Moisture Meter

Parr Oxygen Bomb Calorimeter

Thermo gravimetric Analyser

are available for determination of these properties 70

RICE HUSK 71
RICE HUSK
 RICE HUSK
Free flow -Stored in bunker to feed to boilers

Low bulk density -150 kg/m3

Nearly 60% is used in boilers

Combustion temperature 800-900o C

Good combustion efficiency

Very low oxides of alkali content

Erosion in ID fan due to crystalline silica

72
 RICE HUSK

High amorphous silica content >98%, Low carbon

<3% and high surface area 20-23 sq.m/gm is a
Portland cement substitute upto 12%

High temperature >800o C change amorphous

structure to Crystobalite, tridymite and quartz

Alkali oxides reduces the crystalline structure

formation temperature from 1400 to 800oC

73
PALM TREE WASTE

74
MUSTARD CROP RESIDUE

75
MUNICIPAL SOLID WASTE
(REFUSE DERIVED FUEL)

76
Wood Chips

77
 NOx Reduction

BFBC CFBC

Due to Staging of Air,

NOx levels are lower
in CFBC than BFBC.
NOx in BFBC lower
than PF

Fuel
Air
78