PRODUCTION OF PRODUCER GAS

PREFACE This report provides the information pertaining to the construction, operation and maintenance of a 500kg per hour biomass gasifier system .

The first part of the report provides detailed information regarding the construction and the working of the gasifier system. The second part provides information regarding operation and maintenance of the gasifier system. This also includes operating the thermal equipment with the producer gas.

PART 1

SOLID BIO-RESIDUE GASIFIER SYSTEM

INTRODUCTON: Biomass has been a major energy source prior to the discovery of fossil fuels like coal and petroleum. Even though its rule is presently diminished to developed countries. It is widely used in rural communities of the developing countries, further it is used for limited industrial uses. Biomass besides being in solid form can be converted into gaseous form through gasification.

1.0 CONCEPT AND PRINCIPLE Biomass is a natural substance, which stores solar energy by the process of photosynthesis in the presence of sunlight. It chiefly includes cellulose, lignin with an average composition of C8H10O3 with slight variation depending on the nature of the biomass. The producer gas thus generated during the gasification process is combustive. This process is thus possible

Biomass is a natural substance, which stores solar energy by the process of photosynthesis in the presence of sunlight. It chiefly includes cellulose, lignin with an average composition of C8H10O3 with slight variation depending on the nature of the biomass. The producer gas thus generated during the gasification process is combustive. This process is thus possible in a device called gasifier in a limited supply of air. The clean combustible gas is combusted in a burner to generate heat. In the reactor the biomass process after undergoing drying in the upper zones leaving behind char. The volatilities undergoes oxidation in the combustion zone with air being partially supplied in the surrounding nozzles and the remaining drawn from the open top. The product gases of oxidation further gets reduced by a bed of charcoal and yield a combustible gases having a calorific value of 4.5-5

MJ/KG with an average composition of CO-20%, CH4-4%, H2-20%,CO2-12% and rest N2.

2.0 USAGE OF PRODUCER GAS Thermal energy of the usage the order 4.5 5.0 MJ is released by forming 1ml of producer gas in the burner. Flame temperature of as high as 1680K by optimal premixing of air with gas . For applications which require thermal energy gasifiers can be a good option as a gas generator. Typically the heat generated by 1 litre of fuel oil is generated by 3.5-4 kg of biomass . The exact composition depends upon the energy content of the producer gas , which in turn depends upon the moisture content of the biomass used . Gasifier is an ideal solution for the above situation, where hot gas after combustion can be directly let into the end used equipment.

2.0 SYSTEM DESCRIPTION AND WORKING The overall schematic of the gasifier system is depicted in the figure. The reactor is basically a downdraft system where both gas and feed stock move downward as reaction proceeds. Air required for gasification is partly drawn from the top and the remaining air from the air nozzle surrounding the combustion zone . The required suction for this process is obtained by using the venture effect of spray nozzles (scrubber) and blower. Biomass after drying and pyrolysing in the upper zone of the reactor , undergoes volatile combustion leading fixed carbon or char by the time it reaches the oxidation zone , in the oxidation zone volatiles undergo oxidation with the release of CO2 and H2O. This process undergoes reduction, in the presence of hotbed of

charcoal and yield a combustible gas mixture. The hot gas is led to cyclone and further to cooling in cleaning train, where the raw gas which cools to ambient temperature by a water spray arrangement in cooling section. The gas then flows to the burner near the drier.

Cooling and cleaning of tower is done by following processes 1.Cyclone separator 2.Cooling system 3. Flare

INSTRUMENTATION The system is provided with H2O tube manometer at strategic locations for monitoring the health of gasifier. Pressure switches are provided for pumping the cooled H20 is provided with thermostat and O2 level sensor or controller is provided to indicate O2 percent in producer gas line. These lines are connected to audio visual annunciators. In the event of O2 level exceeding 2%, the operator has to check for air leakage into system. The operation of the screw is automatic with both on/off timers. The controller is set at 400 -440 *C. Poor quality of gas as well as flame failure will generate alarm at pre-set temperature

START UP PROCEDURE Gasifier start up 1.Switch on the instrumentation and control panel. 2.Push the switch to start-up mode, which will automatically open the gas nozzle towards the flare. Manually close fully the main gas valve near the gasifier. Manually open the flare line bypass valve. 3.Keep the main gas feed valve closed near the drier. 4.Switch on the cooling tower pump and fan. 5.Open the reactor top cover. 6.Top the reactor with properly sized biomass. 7.Open all the ignition ports. 8.Hold a flame in the form of a biostack till the char gets red hot. Combustible gas gets compressed within few minutes after the ignition.

9.After successfully torching the reactor close the ignition ports. Open the air nozzle plugs to allow air entry through the air nozzle in the reactor. 10. Light the gas in the flare once the oxygen level falls below 2% the gas. Start-up diffusion mode typically within the reactor. 11. Top the biomass chips in the reactor as they undergo mixing thoroughly at regular intervals of time depending upon the consumption of feed time has to be set manually. Normally the consumption or time period is 10-20 minutes.

STOP MODE Manually switch is in the stop mode energizing. This system is already in emergency mode. 1.Switch off the cooling tower. 2.Close the flare line valve.

RUN MODE 1.Manually push the button and energize the run mode. 2.At-least one of the drier local pumps switch needs to be on. 3.All the drier panels should not be under flame condition simultaneously. 4.Open main gas feed valve. 5.Close the flame line valve.

SAFETY VALVES / INTERLOCKS 1.Push button to switch on flare ignition in start up mode. 2.Flare igniton button works automatically in emergency mode. 3.Main gas blowers are ON when scrubber pumps are ON and not in emergency mode. 4.Alarms are installed to warn if discharge valves are opened for more than 10 minutes. 5.Ash discharge valve is open only if screw valve is OFF.

ASH DISCHARGE VALVES Switches are turns on manually for ash discharge. Interlocks are provided to ensure weather emergency switches are not energized. This allows discharge to take place even in emergency mode. Under normal operation ash top valve is open and bottom valve is closed. During discharge top valve is closed and bottom valve is open. In stop mode both the valves are in closed position.

OPERATION AND MAINATAINANCE

This part explains the operational procedure in the manufacturing process. This includes DRIER OPERATION SHUTDOWN PROCESS MONITORING OF SYSTEM

Maintenance of reactor is very important for the proper functioning of system this includes the functioning of reactor, cooling system, water pump etc. Check for leakages in joints and flanges in very important and regular leak checks must be done.

DOS ENSURE THAT 1. The Charcoal or biomass does not have any extraneous materials like, stones, metal etc. 2. Adequate water level is maintained in all the water seals. 3. Water is being sprayed continuously in the coolers, water jacket of the screw conveyor prior during the run. 4. Coolant water temperature does not exceed 5*C above ambient during the run. 5. Correctly sized dry biomass is being loaded into the reactor and level maintained. 6. There is water in the top cover water seal when it is shut.

DONTS DO NOT 1. Pour water into the reactor under any circumstance to shut down the reactor. 2. Use larger sized and wet biomass other than specified. 3. Expose the bottom of reactor to atmosphere when the reactor is hot. 4. Operate the gasifier at higher load/flow rate immediately after fresh start, if done there is a possibility of biomass not totally converting into char by the time it reaches the air nozzle. Hence follow start up procedure meticulously. 5. Extract more charcoal.