Gasifier Study-2-125 PDF

ITCOT
CONTENTS
A.
ACKNOWLEDGEMENT
B.
CONTENT TABLE
C.
LIST OF TABLES
D.
LIST OF FIGURES
E.
CHAPTERS
Chapter #
DESCRIPTION
PAGE #
Introduction
Methodology
Performance Of Ten Select Gasifier
Installations
4
Vendor Capability And Technology
58
Penetration
5
Barriers To Gasifier Programme And
68
Policy Issues
6
Case Studies Of Successful Installations
Conclusion
F.
ANNEXURES
G.
ENCLOSURES
H.
PHOTOGRAPHS
75
115
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LIST OF TABLES
S.NO.
DESCRIPTION
PAGE #
Letters from BERI
List of State Nodal Agencies Contacted
List of Vendors Contacted
List of installation visited
Design Vs Actual Performance (PEC)
15
Project Cost of Chottomollakhali
23
Installation
7
Three Year Performance of
24
Chottomollokhali Installation
8
Total Project Cost of PSG College
29
Installation
9
Operation & Manual Parameters of PSG
33
College of Technology
10
Actual operation of PSG College of
33
Technology Gasifier System

11
Performance during April 04 March 05
43
of Odanthurai Installation
12
Cost of Energy Generation at Odanthurai
45
Panchayat
13
Nellithurai Plant Performance during
46
August 2004 to March 2005

14
Vendors Supplying Gasifiers
58
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15
Ankur Gasifier Technical Specifications
59
16
Vendor Capability in supplying the system
60
17
Typical Technical Data of an IISc.- Netpro
60
Biomass Gasification Plant

18
Data Table Associated Engineering
62
Electrical / Power Application

19
Grain Processing Industries (India) Pvt.
63
Ltd. Technical Specifications

20
List of Installations with 100% Producer
64
Gas Engine
21
List of Installations with Dual Fuel Engine
65
22
Cost of Biomass at Various Installations
70
23
Performance of VCC for the period July
80
2004 to March 2005

24
Design Vs. Actual Performance of VCC,
83
Kovilpatti
25
Performance of Gosaba Installation
97
Design Vs. Actual

26
MVIT Plant Performance
104
27
Design Vs. Actual Performance of MVIT
108
28
Plant Performance of Bagavathi Bio
110
29
Plant Generation and Consumption Details
111
30
Cost of Production at Bagavathi Bio
113
Energy Ltd.
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LIST OF ANNEXURES
S.NO. DESCRIPTION
1
Detailed list of gasifier collected along with vendor

name
Detailed Questionnaire
Site visit details
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LIST OF ENCLOSURES
S.NO. DESCRIPTION
I
Copy of plant layout drawing of MVIT
II
Performance Data of Odanthurai Panchayat

system from July 2003 to March 2005
III
Performance Data of Bagavathy Bio Power Ltd.

the system till March 2005
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LIST OF PHOTOGRAPHS
DESCRIPTION
1.
BIOMASS STORAGE YARD AT MVIT, BANGALORE
2.
BIOMASS PROCESSING SHED AT MVIT, BANGALORE
3.
GASIFIERS INSTALLED IN CHOTUMULAKHALLI
4.
200 kW BIOMASS GASIFICATION PLANT LAYOUT IN PMCTW,

VALLAM
5.
STORAGE YARD AT VALLI CHLORATE COMPANY, KOVILPATTI
6.
100% PRODUCER GAS BASED CUMMINS ENGINE AT VCC,

KOVILPATTI
7.
DISCUSSION WITH MEDA OFFICIAL, PUNE, MAHARASHTRA
8.
1 X 500 GASIFIER INSTALLATION AT JAGAT ALLOYS PVT.

LTD., KHOPOLI, MAHARASHTRA
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LIST OF FIGURES
S.NO.
DESCRIPTION
PAGE #
PEC Gasifier Performance Analysis
12
PEC Specific Fuel Consumption Vs Gasifier
13
Loading
3
PEC Gasifier Dual Fuel mode Power
14
Generation Cost Breakup

4
PEC Performance Comparison Design Vs
16
Actual
5
Electrical Schematic Diagram of
22
Chottomollakhali Installation
6
PSG College of Technology Performance
30
Data from 3.7.2004 to 30.10.2004

7
Cost of Power Generation at PSG College of
32
Technology (From 3.7.2004 to 30.10.2004)

8
Performance of Jagat Alloys Private Ltd.
39
Performance of Odanthurai Panchayat
44
System
10
Cost of Production at Odanthurai Panchayat
45
11
Performance Valuation of Nellithurai
47
Panchayat
12
Unit Generation Breakup Cost at VIT in %
51
13
Layout of Valli Chlorate Company
76
14
VCC Gasifier Average Plant Load Factor and
80
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Overall Gasifier Conversion Efficiency

15
VCC Biomass Gasifier Plant Performance
81
Data 2002 to 2004

16
Energy Generation and Consumption Details
81
of VCC
17
Unit Generation Breakup Cost in % at VCC
82
18
Electrical Schematic Diagram of Gosaba
88
Installation
19
Gosaba Gasifier Plant Performance data
92
August 1997 March 1998

20
Gosaba Island March Operating Data
94
21
Gosaba Island Power generation cost
96
breakup
22
Gosaba Biomass Gasifier Plant Performance
98
Design Vs Actual
23
MVIT Gasifier Average Plant Load Factor and
105

24
MVIT Gasifier plant performance data
105
2002 to 2005
25
Energy Generation and Consumption details
106
of MVIT
26
Unit Generation Break up Cost in % at MVIT
107
27
Performance of Bagavathi Bio Energy
112
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CHAPTER 1
INTRODUCTION
1.1
Background
Government of Karnataka (GoK), has signed an agreement with International
Funding agencies UNDP (United Nations Development Program), ICEF (India Canada Environment Facility) and Ministry of Non Conventional Energy Sources
(MNES), Government of India (GOI) to implement the project India: Biomass
Energy for Rural India (PMU - BERI) in Tumkur district.
In this connection, it has been planned to set up biomass gasifier decentralized
power generation units in rural areas under the project. To have an appreciation
of technical and financial issues for setting up the project, BERI has initiated to
take up a study on the performance of Biomass Gasifier based power generation
systems in Southern India and Sunderbunds in West Bengal.
1.2
Consultancy
BERI has appointed ITCOT Consultancy and Services Limited, Chennai vide their
letter no: PMU/BERI/34/Enc/2004/1809 dated 8th February 2005, to carry out the
study on Biomass Gasifier based Power Generating Systems in Southern India
and Sunderbunds. Accordingly, ITCOT conducted the study and submits this
report on the performance of the gasifiers
1.3
Structure of the Report

The report has the following structure:
Chapter 1 details the introduction of the project followed by methodology in
Chapter 2. Performance of nine selected gasifier units is detailed in Chapter 3.
Vendors available in Indian market for supplying gasifier and the technology
penetration are detailed in Chapter 4. Chapter 5 details barriers to gasifier
programmes and policy issues. Successful implementations and case studies of 4
units are detailed in Chapter 6 and Chapter 7 concludes the report.
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CHAPTER 2
METHODOLOGY
2.1
Methodology
The methodology adopted for carrying out the study is as follows:
2.1.1 Letters to Nodal Agencies and Vendors

ITCOT drafted letters for Ministry of Non Conventional Energy Sources (MNES),
State Nodal Agencies and vendors, and submitted to BERI. BERI forwarded the
letters to various agencies through letters as indicated in the Table 1 below:
Table 1
Letters from BERI
S. No
Name of the
Letter No
Date
Organisation
1
Ministry
of
Conventional
Non BERI/34/ENE/2004/1882 March 1, 2005

Energy and
Sources, New Delhi

2
March 17, 2005
State Nodal Agencies in BERI 34 ENE 2004 / February

Southern India
BERI/34/En/2004/1917
and
Gasifier
Suppliers
Vendors
1856
2005
/ BERI 34 ENE 2004 / February

1855
22,
22,
2005
2.1.2 Preparation of complete list of gasifiers

The complete list of gasifier installed in South India, West Bengal and
Maharashtra, from the beginning of Ninth Five Year Plan i.e., between 1997 to
till date was collected along with year of installation, location, capacity,
application and present status. The list of gasifiers was obtained from the State
Nodal Agencies as detailed in Table 2 and from Vendors as detailed in Table 3
below:
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Table 2
List of State Nodal Agencies Contacted
No
Letter
Name of the Organisation
Letter Received vide
Date from
Contacted
No. and Date (if any)
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1
March 14,
Agency for Non Conventional
2005
Energy and Rural Technology
(ANERT), Trivandrum, Kerala

2.
March 14,
Karnataka Renewable Energy
2005
Development Limited (KREDL),
Bangalore, Karnataka
3.
March 14,
Maharashtra Energy
BERI 34 ENE 2004/57
2005 and
Development Agency, Pune,
dated 21st April 2005
April 26,
Maharashtra
enclosed with MEDA

letter No. REN/BMS
2005
002/2004-05/1686 dated
11th April 2005
4.
March 14,
Non Conventional Energy
NEDCAP/PD/BG/3552/03-
2005
Development Corporation of
04 dated 28th February
Andhra Pradesh (NEDCAP)
2005
Ltd., Hyderabad, Andhra

Pradesh
5.
March 14,
Tamilnadu Energy
2005
Development Agency (TEDA),
Chennai, Tamilnadu
6.
March 14,
West Bengal Renewable
2005
Energy Development Agency

(WBREDA), Kolkata, West
Bengal
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Table 3
List of Vendors Contacted
No
1
Letter Date
Name of the Organisation
from ITCOT
Contacted
Letter Received
vide No. and
Date
February 24,
Ankur Scientific Energy
Replied via email
2005
Technologies private Limited,
dated February 25,
Baroda, Gujarat
2005 and March

10, 2005
February 24,
Ankur Scientific Energy
Replied via email
2005
Technologies private Limited,
dated February 25,
Regional Office, Kolkata, West
2005 and March
Bengal
10, 2005
February 23,
Centre for Gasification and
Letter dated 16th
2005 and
Propulsion Laboratory (CGPL),
March 2005
Email on March
Indian Institute of Science,
14, 2005
February 24,
Associated Engineering Works
2005
(AEW), Hyderabad, Andhra

Pradesh
5
6
February 24,
Netpro Renewable Energy (India)
2005
Limited, Bangalore, Karnataka
February 24,
Grain Processing Industries
2005
(India) Private Limited, Kolkata,

West Bengal
7
8
February 24,
Cosmo Powertech Private
2005
Limited, Raipur, Chhattisgarh
February 24,
Energreen Power Limited,
2005
Chennai, Tamilnadu
The detailed list of gasifier installations collected along with vendor name and
capacity is enclosed in Annexure 1.
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2.1.3 Preparation of Questionnaire

The detailed questionnaire including Technical and Financial Parameters required
for carrying out the study was prepared and sent to BERI for clarifications/
correction vide letter No. ENERGY/DV/2005 dated February 21, 2005.
The questionnaire with clarifications was received from BERI vide letter No. BERI
34 ENE 004 / 1889 dated March 3, 2005 and the same was used for survey of
gasifier installations across Southern India, West Bengal and Maharashtra. The
detailed questionnaire is enclosed as Annexure 2.
2.1.4 Selection of Gasifier systems for study
As mentioned in Para 2.1.1, the complete list of gasifiers was analyzed and
letters were sent to all the units detailed in Annexure 1 for carrying out site visits
Gasifier systems of various capacities on electrical mode, spread over various
locations were selected for carrying out the study.
Following are the units under various categories selected for the field study.
a. Educational Institutions 6 Installations
b. Gram Panchayat 2 Installations
c. Industrial Units 4 Installations
d. Island under Village Electrification 2 Installations
2.1.5 Site Visit
After receiving the consent of BERI for the units selected, ITCOT Consultants
carried out the site visits. The details visits undertaken along with the date are
enclosed in Annexure 3 and an extract of the same for ready reference is
detailed in Table 4 below.
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Table 4
List of Installation visited (in the order visited)
S. No
Name of the Gasifier Installation
State
M. Vishveswaraiah Institute of Technology, Bangalore
Karnataka
WBREDA Installation of Chotamulakalli
West Bengal
WBREDA Installation of Gosaba
West Bengal
Odanthurai Panchayat, Coimbatore District
Tamilnadu
Nellithurai Panchayat, Coimbatore District
Tamilnadu
PSG Institute of Technology, Coimbatore District
Tamilnadu
Bagavathi Bio Private Limited, Coimbatore District
Tamilnadu
Pondicherry Engineering College
Pondicherry
Valli Chlorate Company, Kovilpatti
Tamilnadu
10
Periyar Maniammai College of Technology for
Tamilnadu
Women, Vallam (Phase I and Phase II)

11
GB Food Oils Limited, Pudupatty
Tamilnadu
12
Jagat Alloys Private Limited, Savroli Village, Khopoli
Maharashtra
13
Vellore Institute of Technology, Vellore
Tamilnadu
Of these 14 installations, 9 installations are discussed in Chapter 3, while the

balance 4 units are discussed in Chapter 6 under successful Case Studies. Four
installations have been chosen for successful case studies and are detailed
below.
1. Valli Chlorate Company at Kovilpatti, Tamil Nadu

Valli Chlorate Company has been chosen as a successful case study for the
reason that it has revived itself from closure by installing 100% producer gas
based gasifier. The company has also increased its profitability by installing
the gasifier by reducing cost of energy purchased from TNEB.
2. Gosaba Island Installation, Sunderbunds

Gosaba Island installation has been as a successful case study for the reason
that the energy generated from gasifier has turned the socio economic status
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of the Island along with community development. Even when the cost of
energy generation is high, the energy generated from gasifier has played a
pivotal role in improving the life style of the rural masses of Sunderbunds,
where grid penetration is impossible in the near future.
3. M. Vishveswaraiah Institute of Technology installation at Bangalore

In the educational institutions category, MVIT is the oldest gasifier unit
operating successfully for the last three years. The unit also operates for
longer period in a year and has generated more units when compared to
other units.
4. Bagavathi Bio Energy Limited installation at Coimbatore

In the industry sector, the unit that is successful in implementing the gasifier
program is Bagavathi Bio Energy installation at Mettupalayam. The company
has successfully been running as a separate entity to serve the energy
demand of a Textile bleaching unit by installing the system in their premises
without any major problem.
Though other units covered by the study were also operating the gasifiers, the
data available from the units other than the above four is scanty and further,
units were also not willing to share the real performance of the gasifiers. Some
units found the operation not economical on dual mode due to high cost of
diesel, and hence, gasifiers are not run.
2.1.6 Limitation of the Study
Most of the units observed that the data questionnaire was very exhaustive and
the units do not have the classified data. Units in general are very reluctant to
share the actual field data especially the financials and absence of the
authentication letter from MNES added to the cause. Thus, ITCOT consultants
based on the discussions, observations and log sheets filled the data
questionnaire. Some units refused to share any details in the absence of MNES
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letter. This resulted in a considerable delay in the unit visit scheduling and data
collection.
Thus, the study is based only on the data collected during the site visit and not
furnished by the unit.
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CHAPTER 3
PERFORMANCE OF GASIFIERS AT NINE SELECTED INSTALLATIONS
3.1
Name of Installation: Pondicherry Engineering College, Pondicherry
A.
Project Background
Objective
District Rural Development Agency (DRDA), Pondicherry through Ministry of NonConventional Energy Sources (MNES) New Delhi implemented the 1x 100kW
biomass gasifier on electrical mode at the Pondicherry Engineering College (PEC)
campus, to promote gasifier system based academic research projects.
Year of Installation
The plant is installed in June 1, 2004
Location
The engineering college is located at a distance of 10 km from Pondicherry town
Plant lay out Size
5m X15m
Type
Woody biomass down draft gasifier with batch feeding
B.
Technical Specifications
Gasifier (supplier - Associated Engineering works (AEW), Tanuku,
Andhra Pradesh)
i)
Capacity: 100 kW (250 m3/h)
ii)
Biomass fuel consumption: 100kg/h
iii)
Biomass fuel size: 15 mm~75mm
iv)
Moisture: < 20%
v)
Hopper holding capacity: 500kg
vi)
Loading of biomass: manual feeding and intermittent
vii) Gasifier starting: By hand blower

viii) Diesel replacement: average: 70%
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ix)
Gas cooling and cleaning of tar removal, particulates: Water spray

cooler, scrubber, 4 nos. of centrifugal tar removing pumps, service filter
(fabric), additional filter with pebbles
x)
Gas flaring provision before service filter
xi)
Height of reactor 12 ft.
xii) Auxiliary power: 12 hp includes wood cutter of 3 hp, water circulation

pump, and make up water pump, scrubber and centrifugal tar removal
pumps (4 nos).
xiii) Water circulation: 250 litres per minute.
xiv) Recommended biomass fuels: Casuarina, eucalyptus, Subabul, Neem,
Cashew, Coconut shells and any hardwood
xv) Gasifier material of construction: Stainless Steel for nozzle and throat
and MS for Hopper, body and pipe line
xvi) Life of Gasifier: 20 years
xvii) Turn down ratio: 30%
xviii) Starting time from cold start: 30 minutes
Engine (make - Ashok Leyland)
Capacity 151 hp
Manual starting system with battery
Alternator (Make Kirloskar)
KVA: 125, Speed rpm: 1500, Voltage: 415 V
Load: 175 Ampere
Frequency: 50Hz
Power factor: 0.8
Continuous duty, S1 IS: 4722-1992
Electrical panels
The plant is designed to operate on stand alone mode and the gasifier power is
transferred to the college for captive consumption after switching off the state
electricity board supply and by providing suitable interlocks to avoid parallel
operation with the grid. Electrical control panel of 200 Ampere rating is provided
with Molded Case Circuit Breaker (MCCB) of 175 A rating with built in protections
of under voltage, over voltage, over current and earth fault protection. The
10
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college has provided 125 A feeder for supplying auxiliary power for starting of
gasifier plant auxiliaries. The power generated from the Gasifier is transferred by
way of change over switch of 400 A rating in the college electrical control. The
main loading point is administrative block but provision is there is to supplement
the loading in other areas.
C.
Financial Parameters
Building and civil works

(Comprising of fuel storage yard, biomass sizing, gasifier system with DG set,
control panel, water storage tank with filtration) Rs. 6.82 lakhs
For Gasifier system with DG set

DRDA: Rs .21.45 lakhs
MNES subsidy: Rs. 1.50 lakhs
Total Project cost: Rs. 29.77 lakhs

D.
Project Status
The plant was commissioned on June 1, 2004 and was under trial operation from
October 2004 to December 2004 by the supplier, for establishing the guaranteed
performance. On completion of the same the project was accepted by DRDA for
handing over to PEC. It was noted that discussions are underway between DRDA
and PEC on official handing over for subsequent plant operation and
maintenance. The plant has not been functional since January 2005.
E.
Plant Performance Summary for the monitored Period

(8 weeks in November 2004 and December 2004)
Gross Power Generation: 15,995 kWh
Average kW loading: 63.42
Total biomass consumption: 22,630 Kgs
Total diesel consumption: 1,780 litres
No. of Operating Hours: 252 hours
Average diesel replacement: 54%
Average cost of gross power generation: Rs.5.40/kWh
11
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Average PLF: 49.98 %
Average specific biomass consumption: 1.46 kg/kWh
Average specific diesel consumption: 0.12 litre/ kWh
The auxiliary consumption data is not provided and hence, not indicated in
the summary.
F.
Plant Performance Analysis

(a) The plant performance in terms of following indices has been discussed in
the chart given below:
a. Average Gasifier system kW loading
b. Gasifier system overall conversion efficiency %
c. % Diesel replacement
d. Gross power generation cost Rs/kWhr
FIGURE 1 Pondicherry Engineering College
Gasifier Performance Analysis
12
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Observations:
i. The highest average kW loading which has been recorded is 83.38 kW in the
fifth week of the monitored period
ii. The highest loading shows the best diesel replacement at 67% with optimum
power generation cost per kWh ie. Rs. 3.97/kWh
iii. The overall gasifier system conversion efficiency (including gasifier, engine,
Alternator) is also highest in the 5th week due to improved loading over the
previous weeks. This index is arrived based on the following assumptions;
GCV of HSD 10,000 kCal/Kg

GCV of biomass @ 20% moisture while feeding gasifier 3,500
kCal/Kg
GCV of 1 kWh = 860 kCal
iv. The chart indicates poor performance indices due to fluctuations in loading in
the 3rd week of monitored period.
(b) Specific fuel consumption with respect to gasifier system loading is
presented in the following chart.
Specific fuel consumption Vs Gasifier loading
13
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Observations:
i. As stated earlier, 5th week of monitored period has shown best
performance indices with highest PLF at 70.88 %.
ii. PLF is arrived at considering the installed capacity of 100 kW, with daily
operating hours of 8 and 5 days a week
iii. The specific fuel consumption of biomass is 1.08 kg/kWh and for diesel is
0.08 litre/kWh
G.
Cost of Production
The breakup cost for gross power generation is given in the chart below:
Gasifier Dual fuel mode Power Generation
Cost Break Up Cost (Rs./kWh)
Biomass cost
Rs/kWh
1.75
32%
Diesel Cost Rs/kWh

3.46
65%
Operators cost
Rs/kWh
0.19
3%
Observations:
i. In the dual fuel mode of operation the impact of diesel cost is well noticed
in the above pie chart. 65% of the average power generation cost is due to
diesel at an average diesel replacement of 54%.
14
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ii. The share of diesel could be reduced further at higher % of diesel

replacement with the improved loading, as average PLF in the monitored
period is low at 49.98%.
iii. One operator with one helper is considered here and their contribution is
negligible at 3% of the total cost. Based on the discussion, the operator
salary is assumed at Rs. 3,500 per month and salary for the helper is
Rs.1,500 per month.
iv. Repairs and maintenance cost is not considered as the plant is new and it
was conveyed that it is covered under 2 years equipment guarantee with
the supplier for replacement of defective items for the entire gasifier
system.
H.
Performance: Design Vs Actual

Table 5
Design Vs Actual Performance of Pondicherry Engineering College
S. No
1
Performance
Unit
indicator
Average kW loading
Design
Actual
KW
100
63.42
Kg/kWh
1.46
Litre/kWh
0.06
0.12
Percentage
70
54
Average Specific
2
Biomass
consumption
3
4
Average Diesel
consumption
Average % diesel
replacement
15
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FIGURE 4 - Pondicherry Engineering College (1 x 100 kW)

Performance Comparison design Vs actual
1.6
120
1.46
1.4
100
1.2
1
80
70
63.42
0.8
60
54
0.6
40
0.4
20
0.2
0.12
0.06
0
Design
Actual
Average Specific Biomass consumption Kg/kWh
Average Diesel consumption Litre/kWh
Average kW loading
Average % diesel replacement Percentage
The design value is considered at 100 % loading and is compared with

actual performance in the monitored period.
The loading in trial operation is lesser compared to the design value and
hence, the performance could not be better at par with design.
The plant has been operated only for eight weeks and is yet to commence
its commercial operation in full swing. Hence, it is expected to achieve a
better performance in loading, specific fuel consumption and better diesel
replacement with optimum constant loading of 80% and above in future.
16
kW and percentage
kg/kWh and litre/kWh
100
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I.
Summary of notes of discussion with PEC and DRDA:
Both DRDA and PEC conveyed that plant operation in the monitored
period was satisfactory
During the trials the supplier has introduced a fine filter made of pebble
stones after the service filter and before air and gas mixer, for achieving
the desired quality of gas
The power generation was fed to college administrative block, which has
an average load of 65 KW. The administrative block comprises load points
of A/Cs, lighting, computers etc. The load test was carried out from 9.00
am to 5.00 pm in 5 days a week.
The entire gasifier system has been delivered at site in a month time
The supplier has offered 2 years guarantee for equipment against

manufacturing defects
The college has plans to operate the system for academic research
projects under M. Tech, Energy technology programme
The best wood suggested by DRDA is pencil wood
The college has done an analysis on generated Charcoal and is given

below:
) Volatile matter 19.11%
) Ash 22.87%
) Fixed Carbon 58.02%
J.
Issues
The college has a contract demand of 500 kVA from the state electricity
board and the average power cost per kWh is Rs.2.10 (inclusive of
demand charges). The college needs to pay a fixed demand cost of 75%
of contracted demand. The average cost of power per kWh from the
gasifier is Rs.5.40 and is higher when compared to state electricity board
tariff. Hence, the college management is exploring the ways and means of
operating the system not for the purpose of captive power alone but also
for academic research projects under M. Tech energy technology
programme.
17
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The college has expressed its inability to allocate a dedicated team for
operating the gasifier installation and discussions are underway between
DRDA and PEC in launching a tendering process to operate the system
through private operator on O&M basis. However, consumables like diesel,
wood, lubricating oils etc. have to be arranged by DRDA/PEC through
Pondicherry Government. The entire process is yet to be finalized and
hence the system is non-functional since January 2005.
K.
General Issues on site operations

It was observed that the following parameters, which have affected the gasifier
performance, have never been tested at the site:
Moisture of biomass fuels at gasifier feeding point
Emission of tar and particulates level
Effectiveness of cooling and gas cleaning system and Producer gas quality
Calorific value
L.
Vibration and noise levels of the installation
Operating Problems:
In dual fuel mode the problems of filters coarse and fine filters, block
the producer gas line very often and creates reduced producer gas flow
and lead to poor quality, resulting in increased diesel consumption for the
same load.
The coarse and fine filters filled with dry wood dust of different grading
often demands cleaning and changing due to frequent choking.
The fabric filter cloth choking problem is experienced frequently in the

installations
Due to the prevailing dusty atmosphere and poor filtering of gas, often
creates choking of air cooled after cooler in engine. The performance of
water based after cooler, is better in maintenance when compared to air
cooled system, as the fins require more cleaning in these dusty
atmosphere.
18
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3.2
Name of Installation: Chotamulakalli Island, 24 Parganas District,

West Bengal
A.
Project Background
Objective
West Bengal Renewable Energy Development Agency (WBREDA) in association
with MNES, Government of India, Sunderbunds Development Department, Forest
Department, and South 24 Parganas Zilla Parisad decided to install a 500 kW (4
x 125 kW) biomass based power plant and Chotamulakalli has been identified by
the WBREDA as a probable location for setting up the woody biomass based
power plant. This place is situated in Gosaba Block of 24 Parganas District of
West Bengal.
This has been selected, as it is one of the Gateways to the
interiors of Sunderbunds.
The locality has a population of 28,000 with a good market where people from
interior areas come for buying and selling products. This market is a good
commercial Centre in the Sunderbunds area. With the availability of electricity,
many small scale entrepreneurs could develop small industries like mini rice mills,
ice plants, pumping /irrigation and water supply, saw mill, cold storage etc.,
where it is almost impossible to extend the conventional power grid line. The
prime objective of this power plant is to improve socio economic condition of the
local people in Chotamulakalli Island.
This power plant may also be utilized for supplying power to the adjacent areas
of Chotamulakalli by installing 11 kV sub-transmission systems and the areas,
which may get the benefit of electric supply, are mentioned below:
a. Tara Nagar
b. Boro Mullakhali
c. Kachukhalli
d. Hetalbari
e. Kalidaspur
19
ITCOT
The 500 kW woody biomass based power plant was commissioned on 19th
October 2001
Plant lay out Size
2000 sq. ft
Type
B.
Gasifier (supplier Ankur Scientific Energy Technologies, Baroda)
1.
Model: WBG 120
2.
Capacity: 125 kW
3.
Rated gas flow: 300 m3/h
4.
Average gas Calorific value: > 1,000 kCal/m3
5.
Biomass fuel consumption: 96 ~ 120kg/h
6.
Gasification temperature: 1050 ~ 1100 deg. C
7.
Indicative gasification efficiency:

Hot gas mode: > 85%
Cold gas mode: > 75%
8.
Temperature at gasifier outlet: 250 ~ 400 deg. C
9.
Biomass fuel size:

Minimum diameter 10 mm and length 10 mm
Maximum diameter 60 mm and length 75 mm
10.
Moisture: < 20% on wet basis
11.
12.
Loading of biomass: intermittent manual feeding per hour
13.
Ash removal: Continuous through proprietary control and water seal
14.
Gasifier starting: Through scrubber pump/blower
15.
Specific fuel consumption: 250 ml/kWh full diesel mode
16.
Indicative diesel replacement: average 65 ~ 75% depending on

operating load
17.
Engine conversion efficiency: 25%
20
ITCOT
18.
Gas cooling and cleaning of tar removal, particulates: Venturi scrubber

with water re-circulation and ultra clean gas for power generation
mode through proprietary and fine filters
19.
20.
21.
Auxiliary power: 8 kW
22.
Water circulation: 250 litres per minute.
23.
Recommended biomass fuels: Casuarina, eucalyptus, subabul, Neem,

24.
Gasifier material of construction: Stainless Steel for nozzle and throat

25.
Life of Gasifier: 5 years
26.
Turn down ratio: 30%
27.
Starting time from cold start: 30 minutes
28.
Maximum permissible particulate: 50 mg/m3
29.
Typical producer gas composition (%)

CO=19 +/- 3%
N2 50%
CO2=10 +/- 3%
H2=18 +/- 2% CH4=up to 3%
Engine (make - Greaves)
Capacity 160 kVA
Mechanical B1 class governor
Alternator (Make Crompton Greaves)
KVA: 160, Speed rpm: 1500, Voltage: 415 V
Load: 222 Ampere, Frequency: 50Hz
Power factor: 0.8
Electrical Systems
Chotamulakalli Island was an un-electrified village until this project was
commissioned, and the plant was designed to operate on stand alone mode for
village electrification purpose, as extension of the conventional grid power is
impossible.
21
ITCOT
FIGURE 5 - Electrical Schematic Diagram
Feeder 1
Provision given for
future expansion
415 V bus
Bus
coupler
DG sets 1, 2, 3 and 4
The power generated from the five DGs can be synchronized at the 415 V bus
and is taken through feeders 1 with a step up transformer of 315 kVA for power
distribution at 11 kV. The existing 11 kV distribution circuit comprises of 1 km,
and 415 V distribution circuit comprises of 5 km. The 415 V distributions has 1
no of 100 kVA and 1 no of 63 kVA step down transformers located at various
load ends. During the discussion it was informed that distribution loss has been
estimated at 8%. The plant has been provided with a bay for second 315-kVAdistribution transformer. WBREDA has approached MNES for second phase grid
extension of 15 km.
Electrical control panel of 2000 Ampere capacity rating and each DG set is
provided with Molded Case Circuit Breaker (MCCB) of 300 A rating with built in
protections for under voltage, over voltage, over current, earth fault protection
and reverse power. The synchronizing panel has synchroscope and the operators
check synchronizing relay and synchronizing operation manually. The outgoing
feeder and bus coupler is provided with 630 A ACB. The distribution panel is
22
ITCOT
provided with Enercon make EM 3360 2 nos for registering power at the feeder
levels.
C.
Table 6
Project Cost of Chottomollokhali Installation
S. No
1
Items
Land
Unit
Cost Rs lakh
1 acre
150.00
Fuel storage yard
2,500 sq ft
Gasifier system with DG
7,000 sq ft
Power evacuation
315
system
100 kVA and 63 kVA
kVA
transformer,
distribution transformers
associated
electrical
system
Total project cost: Rs.150 lakhs
Source of funds:
75% of the project cost from MNES
25% of the project from West Bengal State Government
Power evacuation cost:
Cost for 11 kV (HT) distribution: Rs 2.5 lakhs/km
Cost for 415 V (LT) distribution: Rs 1.5 lakhs/km
The plant has 5km of LT line and 1 km of HT line. WBREDA has planned to
expand the distribution network by another 10 km with the support of MNES in
second phase.
23
ITCOT
Consumers and Tariff structure

The island has an area of 25 sq km with a population of 15,000. It was informed
that around 350 consumers are availing this power supply and are grouped as
below.
Domestic: Rs.4.00/kWh
Commercial: Rs 4.50/kWh
Hospital: Rs.4.50/kWh
Ice factory: Rs 5.00/kWh
Small industries like band saw mill and others: Rs 5.00/kWh
Deposit fees towards service connection @ Rs 500/consumer and Rs 20/month

as meter rent is charged from the consumers. The above are flat tariff charges
without taxes. Around 95% of the customers are coming under domestic group.
Operation and Maintenance cost
Based on the discussion with WBREDA, the past operating data is summarized
below in Table 7:
Table 7
Three Year Performance of Chottomollokhali Installation
S. No
Items
2002
2003
2004
Average Processed biomass fuel tonnes
120
144
180
Average fuel cost Rs/kg
1.00
1.00
1.00
Average Diesel in Kilo litres
12
15
18
Average Diesel price Rs/litre
15
20
29
No. of operators
Average Operators salary/annum Rs lakh
2.40
2.40
2.40
Electricity generation cost Rs/kWhr
2.75
3.50
4.50
Total revenue generated Rs lakh
4.20
6.00
7.20
Total expenditure Rs lakh
5.20
7.30
9.00
10
Net deficit Rs lakh
1.00
1.30
1.80
24
ITCOT
D.
Chotamulakalli Power Plant Operation

The power plant though, has an installed capacity of 4 x 125 kW, but presently
one system is operated, due to the non-completion of grid extension network.
The power plant is starts at 5.30 pm and stops at 11.00 pm, and the peak
loading is around 110kW at 8.30 pm, and after 6.30 pm the loading drastically
reduces to 60%.
Society for plant operation
Eight member beneficiary committee comprising of personnel from Panchayat
head, Panchayat Samithi, WBREDA, political party, consumer representative,
Sunderbunds development board and state government, manage the power
plant..
Diesel replacement
The plant operating data was not provided by WBREDA and the plant was not in
operation during the site visit of ITCOT Consultants (Visit was made at 2.30 pm)
and hence, no reading was taken from logbook. WBREDA informed that at peak
load of 110 kW in one gasifier, following would be the consumption levels, as
experienced by them:
E.
Total diesel consumption at peak: 10 litres/hour
Total biomass consumption at peak: 100 kg/hour
Total diesel consumption on diesel mode: 26 litres/hour
Diesel replacement at peak load of 88%: 62%
General Issues
It was informed that fluctuating demand was a main attribute for the poor
performance of the gasifier. The load points are predominantly lighting
(domestic, commercial, and street) fans, irrigation pumps, commercial
establishment like education institutions and hospital. Before this power
plant, consumers were using SPV for lighting systems and fans.
Though three gasifiers were replaced with new gasifiers in 2002 (Gasifier
1,3 and 5), it was informed that gasifier three has still problems in the
25
ITCOT
coarse & fine filters, often leading to pressure build up and reduced flow
of producer gas. Other two units also have intermittent problems related
to filters.
Fabric filter, which exists before the air fuel mixture, also has similar
problems of choking in all the working gasifiers.
WBREDA has conveyed that the whole system of gas cleaning and cooling
needs a thorough study on the system design and actual performance. It
was also conveyed that vendor had never checked the performance
indicators like gas quality, tar and particulate emissions at a specified
loading, vibration levels, and wear & tear of the engine on poor gas
quality.
Due to the frequent problems in the filters and resultant poor gas quality,
operators were forced to operate on diesel to maintain the same load.
The entire operation of DG set and gasifier is manual; hence, if producer

gas generation is of poor quality then it warrants more attention in
operating the DG set on diesel mode, as more operator intervention is
required. . This could result in increased cost of power generation.
The operating nature is such that any fall in the gas flow due to filter
choking will throw an impact on the sudden reduction of frequency and
this has to be immediately attended to by the operator to increase the
diesel flow to maintain loading. Hence, gasifier operation with frequent
filter problems poses a great challenge to operators.
The problems faced in the coarse and fine filter is due to the sizing of
sawdust, which is used as filter medium for removal of tar and other
particulate. Incorrect sizing could lead to blockage of sawdust at the mesh
pores and reduction in gas flow.
Engine after-cooler has a direct impact on the engine efficiency and one
DG set at Gosaba has air-cooled-after-cooler and due to dusty atmosphere
with biomass fines, air-cooled-after-cooler fins are found to be choked
very often and demand cleaning of filter once a week.
R&D on gasifier reactor and material thickness should be conducted.
26
ITCOT
3.3
Name of Installation: PSG College of Technology, Coimbatore,

Tamilnadu
A.
Project Background
Objective
PSG college of Technology, Coimbatore through Ministry of Non-Conventional
Energy Sources (MNES) New Delhi implemented a 1x 100kW biomass gasifier on
electrical mode at the PSG foundry campus, Neelambur to partially meet the
foundry electrical energy requirement and also to promote gasifier system based
academic research projects at the college.
Year of commissioning
The plant is commissioned in 30th July 2004.
Location
The gasifier is located in PSG foundry unit at a distance of 10 km from
Coimbatore town.
Plant lay out Size
12.1 m X 9.0 m
Type
Open top, down draft solid biomass gasifier.
B.
Gasifier (Supplier Netpro Renewable Energy (India) Pvt Ltd,
Bangalore)
1.
Capacity: 100 kW
2.
Biomass fuel consumption: 135 kg/hr
3.
Specific fuel consumption: 1.25 kg/kW +/_ 0.1
4.
Bulk density of fuel: 250kg/m3
5.
Biomass fuel size: 20mm x 20mm x 60 mm (max). Small particles

(10mm x 10mm x 15mm) could be added but limited to maximum of
5 %.
6.
Gas quality with standard biomass
7.
Moisture: < 15%
27
ITCOT
8.
Gas cooling: Cold & Chilled Water spray -180 lpm (10 15 C)
9.
Tar & Particulate matter removal by: Cyclone separators, scrubber,

chillers & fabric filter (Non woven polyester cloth which retain dust
particles up to 5 micron size- Fabric filter is approximately 4 m2)
10.
Chilled water spray: 150 lpm
11.
Moisture removal: Moisture traps-2nos
12.
Gas flaring provision before fabric filter
13.
Height of reactor: 5.5 m
14.
Auxiliary power: 18 kW includes raw water 3 HP- 3nos, 2 HP- 3 no,

Blower -2HP, Screw conveyor for ash removal- 1HP, ETP- 2HP CT fan
2HP -2nos,
15.
Recommended biomass fuels:
Besaram (Ipoemia), coconut shell,
Casuarina (Equistifolia), Eucalyptus, Mulberry stalk, Lantana camara,

Silver oak, Jungle wood, saw dust briquettes
16.
Gasifier material of construction: high temperature ceramic and stain
Engine (make Cummins India)
Capacity: 140 kVA
Governing system: Hydraulic governor with manual air fuel adjustment

and using Battery operated starting system
Alternator (Make Stamford)
KVA: 140
Speed rpm: 1500
Voltage: 415 V +/-2.5 %
Frequency: 50Hz
Power factor: 0.8
Self excited, self regulated brush less design
Type of circuit breaker: Molded case circuit breaker

Protection system: Earth leakage relay with CBCT
The system is provided with voltage, current and energy meter.
28
ITCOT
C.
The system is installed in the PSG foundry campus itself and hence, land value is
taken as nil. The unit does not have Biomass sizing unit as the unit is purchasing
processed biomass. The break up cost of the system is given below in Table 8.
Table 8
Total Project Cost of PSG College Installation
S. No
System
Area
Cost in Rs.
lakhs
Gasifier & auxiliaries
Gas engine, Alternator &
5m x 5m x 7.5m
14.500
5.3m x 9.0m x 7.5 m
15.500
auxiliaries
D.
Power distribution system
1.500
Effluent treatment system
0.350
Pumps
0.386
Total
32.286
MNES subsidy on item 1 & 2
50 %
Project Status
The plant was commissioned on July 30, 2004 and put under operation
intermittently. The system was not operational during the site visit due to
problems in the engine in taking load.
E.
Plant Performance Summary available for the Period (3/7/2004 to

30/10/2004)
The operating performance of the system as on 30/10/2004 is given below.
Engine Operating Hours: 263 Hrs.
Gasifier Operating Hours: 128 Hrs.
Total units generated: 4,363 units
Total biomass consumption: 14,562 kgs.
Average plant load, based on operating hours of the engine: 35.6%
29
ITCOT
Average cost of gross power generation as reported in the questionnaire:

Rs.3.25/ kWh

(a) The plant performance in terms of following indices has been discussed in
the chart given below:
1. Specific fuel consumption- kg/kW
2. Gasifier system overall conversion efficiency %
3. % Loading of the system
4. Cost of generation Rs/kWh
FIGURE 6 - PSG College of Technology
Performance Data from 3.7.2004 to 30.10.2004
10.0
60.0
Date
50.8
46.2 45.8
44.3
43.2
41.9
40.0
37.4
38.5
34.0
35.2
3.0
36.3
3.2
30.0
2.0
2.3
30.0
27.2
25.9
2.2
2.6
11
9
11
23.4
2.2
1.8
14
12
8
3.8
34.0
2.8
50.0
47.2
2.0
2.0
12
12
2.5
2.3
1.9
13
1.8
13
14
1.7
11
20.0
11
10
10.0
1.0
0.0
Date
Specific consumption kg/kW
%of loading
30
Overall efficiency
% of loading & Overall

efficiency
Specifc fuel consumption-kg/kW
F.
ITCOT
Observations:
1. Loading plays an important role in the viability of the system
2. The highest operating kW, which has been recorded is 50.8 kW, while the
average operating load is 37%
3. The average auxiliary consumption is around 43 % of the total gross
generation, which in high due to low operating load
4. The average biomass consumption is 2.4 kg/kW, which is much higher
compared to the design value of 1.3 kg/kW, which may be due to low
operating load and high down time of the engine
5. Though the reported average power generation cost per kWh is Rs. 3.25,
the actual power generation cost estimated during the above operating
period is Rs.5.84/kWh
6. The overall gasifier system conversion efficiency (including gasifier,
engine, Alternator) is also in the range of 8-14%, which is also low due to
poor loading
7. The chart indicates poor performance indices due to fluctuations in
loading
G.
Cost of Power Generation

Cost of power generation with respect to gasifier system loading is presented in
the following chart.
31
ITCOT
FIGURE 7 - PSG College of Technology

Cost of Power Generation
(From 3.7.2004 to 30.10.2004)
R &M
0.5 8%
Man
Power
0.14 2%
Fuel 5.84
90%
Fuel
Manpower
R&M
Observations:
The fuel component of cost of generation based on the operating data of

log book is very high due to low loading and operating period of the
gasifier system though the data provided in the questionnaire is Rs 2.5
/kWh based on the specific consumption of Biomass of 1.43 kg/kW at the
rate of Rs.1.75 per kg
The break up details of R & M is not provided and taken as Rs.0.5 /kWh,
based on the questionnaire
The cost of manpower is very less as one operator and supervisor is in

charge of the project and their contribution to cost of unit operation is
negligible at 2% of the total cost. Based on the discussion, the operator
salary is taken at Rs. 1000 per month and supervisor at Rs.2500 per
month
32
ITCOT
H.
Technical performance data

Operators manual has been referred for typical operating design pressure at
various sections of the system during normal operation and the details are given
below in Table 9 and Table 10.
Table 9
Operation & Manual Parameters of PSG College of Technology
Pressure in mm of H2O
Biomass
Load
consum
(kW)
ption
Kg
Inlet to
Gas flow
rateg/s
Across
Reactor
R.W.
Venturi in
(P1) in
Cooler
mm
mm
(P2) in
Outlet to
Chilled
cooler in
mm
mm
50
55 +/- 5
38 +/- 5
30 +/- 10%
60 +/- 10 20+/- 10%
100+/-10%
70
80+/-5
50+/-5
55+/-10%
70+/-10
25+/-10%
85+/-10%
85
90+/-
65+/-5
80+/-10%
80+/-10
30+/-10%
80+/-10%
100
110+/-5
75+/-5
110+/-10%
90+/-10
35+/-10%
80+/-10%
110
121+/-5
85+/-5
135+/-10%
100+/-10
40+/-10%
85+/-10%
120
132+/-5
90+/-5
160+/-10%
110+/-10
45+/-10%
85+/-10%
Gas flow g/s: Venturi constant x sq. root of pressure drop at Venturi
Based on the logbook, the following actual operating data is noted for a typical
day (13/7/2004) is given below.
Table 10
Actual Operation of PSG College of Technology Gasifier System
S. No
Parameter
Unit
Value/Range
Load
KW
11 ~ 73
Gas flow (Based on Venturimeter)
g/sec
32 ~ 84
Differential pressure across Venturimeter
Mm H2O
25~ 175
Reactor exit P1
Mm H2O
10 ~ 30
33
ITCOT
Table 10 Contd..
S. No
I.
Parameter
Unit
Value/Range
Raw Water Cooler outlet P2
Mm H2O
20 ~ 60
Chiller outlet
Mm H2O
55 ~115
Reactor exit temperature
258 ~ 586
Moisture Trap exit temperature
14~ 21
Charcoal
Kg/day
6~10
O2
0~1
10
Voltage
Volts
415~ 420
11
Currents
Amps
25~ 120
12
Frequency
Hz
47~ 51.5
13
Water Temperature
60~ 75
14
Oil Temperature
60~ 80
15
Oil pressure
Psi
40
16
Exhaust Temperature
360 ~ 450
17
Speed
Rpm
1400 ~1500
Issues:
i.
The gasifier with 100 % producer gas engine from Cummins is the first of
its kind and the system is yet to get stabilized.
ii.
The load connected to the engine is foundry (Sand blasting -35 kW,
Lighting load-20 kW, Auxiliary of gasifier system -20 kW) and facing
fluctuating load predominantly due to sand blasting (For every 8 minutes,
blower will be on for 3 sec.) and during overload, the gas quantity is not
sufficient to meet the demand and hence, the engine trips. It was observed
that engine could not take load more than 40kW often. The following are
some of the problems encountered during the period.
a) Screw conveyor for ash removal was getting choked often, which may be
due to frequent on/off of the gasifier system
b) Fabric filter is getting blocked often
c) Biomass size is reduced from 30 mm x 20 mm to 20mm x 20mm
34
ITCOT
d) It was noted that the management was trying to synchronize the system
with Electricity Board recently with the technical input of PSG technology
but could not succeed
e) It was observed that no trained man power is available for operating the
system and PSG technology was providing technical support as and when
required
35
ITCOT
3.4
Name of Installation: Jagat Alloys Private Limited, Khopoli,

Maharashtra
A.
Project Background
Objective
Jagat Alloys Private Limited (JAPL), Savroli Village, Khopoli planned to set up 2 x
500 kW gasifier for captive consumption. JAPL has set up only 1 x 500 kW
gasifier to meet the load of Ferro Alloy Plant.
Year of commissioning
The plant is commissioned on July 4, 2001.
Location
The unit is located in Savroli Village 120 km from Pune.
Type
Open top, down draft solid biomass gasifier
B.
Gasifier (Supplier Cosmo Powertech Private Limited, Raipur)
1.
Capacity: 500 kW
2.
Rated Gas Output: 1250 Nm3 / h
3.
Calorific Value of Gas: 1000 1200 kCal/ Nm3
4.
Biomass to gas conversion Efficiency: 70%
5.
Biomass fuel consumption: 400 kg/hr
6.
Specific fuel consumption: 0.8 to 1.2 kg/kW
7.
Bulk density of fuel: 250kg/m3 on dry basis
8.
Biomass fuel size: Minimum 100 mm and Maximum 150mm of any shape
9.
Moisture: < 20%
10. Water required: 300 350 litres per hour

11. Turn Down Ratio: 1:2
12. Contaminants in clean gas: Less than 100 mg/Nm3
13. Height of reactor: 10 feet
14. Auxiliary power: 10 units per hour
36
ITCOT
15. Recommended biomass fuels: Any woody biomass or low ash biomass
briquettes
16. Gasifier material of construction: Reactor with 5mm thick MS plate and
lower part made of 8mm thick MS Plate with air nozzle of SS make.
17. Hopper Capacity: 1500 2000 kg of biomass
Engine (make Yanmar)
Model No: T 220 ST
D1 Water Cooled
TCIC 6 Cylinder Engine
Speed 750 rpm
Compression Ratio: 13:1
Injection System Make and Model: Diesel KIKI DL 90S03N75
Period of Operation:
Diesel Mode: 1500 Hours
Dual Fuel Mode: 1000 Hours
Rate of Lubricating Oil Consumption: 500 CC per hour
Alternator (Make Taiyo)
C.
Rating: 560 kW
Type: FE 45 E - S
Speed rpm: 1500
Voltage: 450 V
Current: 898 Amps
Frequency: 50Hz
Power factor: 0.8

The system is installed in the rear side of the unit and the cost of building and
civil works is taken as nil.
The unit does not have Biomass sizing unit as the unit is purchasing processed
biomass.
37
ITCOT

Total Cost: Rs. 268.68 Lakhs
Equity: JAPL: Rs.67.17 lakhs
Loan from Banks including MNES Subsidy: Rs. 201.51 Lakhs
MNES subsidy: Rs. 20.40 lakhs (Source MNES Letter to MEDA)
a) Gasifier Subsidy: Rs. 8.5 Lakhs
b) Instrumentation: Rs. 0.15 Lakhs
c) Cooling and Cleaning System: 2.50 Lakhs
d) Automation Subsidy: 1 Lakh
e) Others (Pre processing Effluent treatment): 2 Lakhs
f) Dual Fuel DG Set: 6.25 Lakhs
D.
Project Status
The plant was commissioned on July 4, 2001 and put under operation
intermittently. The system is not in operation for the past two years.
E.
Plant Performance Summary available for the Period (1/8/2001 to

10/09/2001)
Gross Power Generation 1,57,334 kWh
Average kW loading: 47.96%
Total biomass consumption: 1,87,935 Kgs
Total diesel consumption: 19,010 litres
Average diesel replacement: 58%
Average specific diesel consumption: 0.12 litre/ kWh
38
ITCOT
F.

The plant performance in terms of following indices has been discussed in the
Energy Generated and Biomass Consumption in

kgs
chart given below:
8000
1.
Biomass consumption in kg.
2.
Diesel consumption in litres and
3.
Energy generated in kWh

FIGURE 8
Performance of Jagat Alloys Private Limited
7000
700
600
6000
500
5000
400
4000
300
3000
200
2000
100
1000
8/
1
8/ /01
3
8/ /01
5
8/ /01
7
8/ /01
8/ 9/0
1 1
8/ 1/0
1 1
8/ 3/0
1 1
8/ 5/0
1 1
8/ 7/0
1 1
8/ 9/0
2 1
8/ 1/0
2 1
8/ 3/0
2 1
8/ 5/0
2 1
8/ 7/0
2 1
8/ 9/0
31 1
9/ /01
2
9/ /01
4
9/ /01
6
9/ /01
9/ 8/0
10 1
/0
1
Biomass Consumption in Kgs

Diesel Consumption in Litres
Energy Generated in kWh
Observations:
1. In the figure it could be seen that fuel replacement for unit generation
follows the same pattern with respect to biomass consumption.
2. The highest loading has taken place on 3rd of September 2001.
3. The average biomass consumption is 1.19 kg/kW, which is almost the
same to design value.
39
ITCOT
4. Though the reported average power generation cost per kWh is 3.25, the
actual power generation cost estimated during the above operating period
is Rs.4.6/kWh and this mainly because of diesel price.
G.
Issues:
JAPL for setting up 2 x 500 kW gasifier based power generating system has
approached Consultant to prepare Detailed Project Report (DPR) for submitting
the same to MEDA, MNES and Development Credit bank limited. Central Financial
Assistance (CFA) of 40.80 lakhs was approved by MNES for the year 2000 01.
50% of 40.80 lakhs i.e. 20.40 lakhs was sent to MEDA from MNES for granting
the subsidy. JAPL has mobilized equity through shares for their plant expansion
& gasifier installation and arranged loans other than MNES subsidy through
Development Credit bank limited.
JAPL has installed 1 x 500 kW gasifier and received 50% grant from 20.40 lakhs
i.e., 10.20 lakhs from MEDA. JAPL has commissioned 1st Phase 500 kW and
provided Rs. 8 lakhs as advance to Gasifier Supplier Cosmo power tech for
installing second phase.
However, MNES has asked for bank guarantee from JAPL to pay the final 50%
for 1st Phase and as bank guarantee could not be provided by JAPL though
nationalized bank (as Development Credit bank were their bankers a non
Nationalized bank) the second payment got delayed. This has forced the
company into financial crunch. Further to it, MNES after installation has
requested for type certificate of Cosmo power tech gasifier, adding further delay
in receiving the subsidy.
After receiving the type certificate, MNES has requested IIT Mumbai to provide
common performance report (CPR) on gasifier performance. During trial, the
replacement of diesel was 58%. The reason indicated for lesser diesel
replacement was the wetness prevailed in the biomass used as the trial was
40
ITCOT
taken during rainy season and hence CPR submitted by GARP, IIT was rejected
by MNES and added further delay. Then final trial run was conducted on 2nd April
2002 and diesel replacement was achieved around 71%.
MNES has sanctioned the remaining subsidy for 1st Phase; however, JAPL has
given up 2nd Phase and then requested MNES to cancel the second phase grant
for another 500 kW, due to their own financial crunch and other hiccups in
receiving the grant.
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3.5
Name of Installation: Community Based Gasifier Project, Odanthurai,

Coimbatore District
A.
Project Background
The project is commissioned to meet the energy requirement of raw water
pumping station of Odanthurai Municipality.
The Gasifier system of 9kW is
supplied by Ankur. The system is self-regulated and excited engine supplied by

DIPCO and later replaced with Field Marshall as the engine could generate 7HP
and the matching Compton Greaves Alternator.
The project cost is as follows
B.
The project cost is Rs.3.71lakhs
Panchayat contribution-Rs. 1.75 lakhs
MNES subsidy-Rs. 1.35 lakhs
Gasifier (Supplier Ankur Scientific Energy Technologies Private
Limited, Baroda)
1. Model Ankur Gas 9 WBG 15
2. Biomass Consumption: 13 kg./ hr.
3. Fuel: Hard Woody Biomass
4. Calorific Value of gas: 1100 1300 kCal/ Nm3
Alternator (Make Crompton Greaves pf:0.8)
C.
Rating: 15 kVA Alternator
The project cost is as follows:
The project cost is Rs.3.71 lakhs
Panchayat contribution: Rs.1.75 lakhs
MNES Subsidy Rs.1.35 Lakhs
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D.
Plant Performance
The project is commissioned on 5th April 2004 and the performance data of the
system till 29th March 2005 is given in Enclosure II, and the consolidated data
is given below in Table 11.
Table 11
Performance during April 04 March 05 of Odanthurai Installation
Biomass
Month
Power
consumption consumption-
Specific
biomass
consumption
No of operating
hrs of the
-kgs
kWhr
Apr-04
660
344
1.92
57.50
May-04
1,223
587
2.08
116.20
Jun-04
787
395
1.99
78.45
1,070
535
2.00
102.00
Aug-04
876
473
1.85
80.30
Sep-04
850
506
1.68
90.80
Oct-04
360
201
1.79
35.50
Nov-04
650
346
1.88
67.60
Dec-04
403
198
2.04
39.75
Jan-05
390
341
1.14
34.50
Feb-05
621
341
1.82
62.25
Mar-05
755
569
1.33
74.90
8645
4835
Jul-04
Total
Kg/kWh
system
840
The above data on the performance is given in a graph shown below.
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FIGURE 9 - Odanthurai
Performance of Odanthurai System
P e rfo rm a n c e o f s y s t e m
2 .5 0
2 .0 0
1 .0 0
0 .5 0
S p e c if ic b io m a s s
c o n s u m p t io n
Wood
c o n s u m p t io n ,
P o w e r g e n e r a t io n
1 .5 0
A p r - 0 4 M a y - J u n - 0 4 J u l- 0 4
04
A ug04
W o o d c o n s u m p t io n
S e p - O c t- 0 4 N o v 04
04
P oMwo en rth g e n e ra t io n
D e c - Ja n -0 5 Fe b -0 5 M a r-0 5
04
S p e c ific b io m a s s c o n s u m p t io n
The above table indicates that specific biomass consumption decreases over
the period of time
The power generation is low during the period of October & December which
may be due to low operating days which may be due to weather conditions
The power generation is low with high specific biomass consumption during
summer and low during winter seasons
E.
Cost of Production
The cost of production before implementing the project and after biomass
gasifier system is given below in Table 12.
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Table 12
Cost of Energy Generation at Odanthurai Panchayat
No
Before Gasifier system
1.
Electricity
After Gasifier system
Rs.3.5 per kWh
Biomass cost
Rs.0.450*
charges
2.
Labour
Rs.0.446 per kWh
Labour
Rs.0.664
3.
Maintenance
Rs.0.071 per kWh
Maintenance
Rs.0.281
Total
Rs.4.017
Total
Rs.1.395
Savings: 65%
* Biomass consumption is @1.5kg@Rs.300 per ton
The breakup of cost of production is given below.
Figure 10 Cost of Production at Odanthurai Panchayat
20%
32%
48%
Biomass cost
Labour
Maintenance
It is observed that the labour cost contribute maximum in the cost of

production, while maintenance cost is the lowest
The raw material cost is low as the biomass is being collected and sized
locally using self-help group.
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3.6
Name of Installation: Community Based Gasifier Project, Nellithurai,

Coimbatore District
A.
Project Background
Location: Nellithurai, Coimbatore district
The project is commissioned to meet the energy requirement of the raw water
pumping station at Nellithurai Municipality and the lighting of the surrounding
area. The total power requirement is 3 HP and 2 HP for water pumps and a
lighting load of 3 kW.
B.
The Gasifier system supplied by Ankur . The system is 10kW self regulated &
excited engine of DIPCO with matching Alternator.
C.
Financial parameters not provided.
D.
Performance
The project was commissioned in August 2004 and the performance data of the
system till March 2005 is given in Enclosure III and the consolidated data is
given below in Table 13.
Table 13
Nellithurai Plant Performance during August 2004 to March 2005
No
Month
No of
days
Biomass
Units
Hrs of
generator
Specific Biomass
consumptionkg/kW
Aug.04
13
645
436
10,383
1.48
Sep.04
250
172
9,980
1.45
Oct.04
20
250
215
37,204
1.16
Nov.04
28
580
193
9,980
3.01
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Dec.04
19
870
555
45,398
1.57
Jan.05
19
640
560
37,204
1.14
Feb.05
18
1,230
573
26,787
2.15
Mar.05
30
3,500
1123
Total
156
7,965
3,827
3.12
176,936
The above data is represented in the graphical form below.

FIGURE 11 Performance Valuation of Nellithurai Panchayat
3.50
3500
3.00
3000
2.50
2500
2.00
2000
1.50
1500
1.00
1000
0.50
500
Aug.04Sep.04Oct.04Nov.04Dec.04 Jan.05Feb.05Mar.05
Biomass
Units
Month & Year

specific Biomass consumption
47
consumption-kg/kW
Power generation units in kWh
4000
Specific biomass
Biomass consumption-kg &
Performance Valuation
ITCOT
The above graph indicates the following.
The biomass consumption is lower for the initial period due to low loading.
The power generation and biomass consumption is higher for December

to March period.
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3.7
Name of Installation: Vellore Institute of Technology, Vellore
A.
Project Background
Objective
Vellore Institute of Technology (VIT) has installed a 90 kWe Gasifier for
generating power for captive consumption in the hostels and to carryout R & D
activities in the field of Renewable Energy.
The unit was installed during 2003.
Location
VIT is located at Vellore, which is 145 Kms from Chennai.
Plant lay out Size
The total plant area is 2,100 Sq feet covering 400 sq feet for fuel processing yard
and 600 sq feet for Gasifier System and DG Set
Type
B.
Gasifier (supplier Netpro Renewable Energy Private Limited)
iii.
Capacity: 100 kW
iv.
v.
vi.
Moisture: < 15%
vii.
viii.
Gasifier starting: Manual
ix.
Diesel replacement: average: 75 - 85%
x.

cooler, cyclone separator, scrubber, sand (coarse and fine) filter, fabric
filter, 2C output - water chiller
xi.
Gas flaring provision before gas entry into engine
xii.
Height of reactor: 2.9m
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xiii.
Recommended biomass fuels: Casuarinas, eucalyptus, Julia flora and

any hardwood
xiv.

and SS 304 for Hopper, body and pipe line
xv.
xvi.
Turn down ratio: 1:3
xvii.
Starting time from cold start: 15 - 30 minutes
xviii.
Conversion Efficiency (Fuel to Producer Gas): 92%
xix.
Conversion Efficiency (Engine): 30%
xx.
Auxiliary Consumption: 32 HP for pumps
Engine
Make: Kirloskar
Capacity: 90 kW
Alternator
C.
Make: Kirloskar
Capacity: 125 kVA, Speed: 1500 rpm, Voltage: 415 V
Frequency: 50 Hz, Power Factor: 0.8, Insulation: Class H
Voltage Regulation: Automatic

The college has allotted land for installing gasifier.

Capital Subsidy: Rs. 1.35 Lakhs

D.
Project Status
The plant was commissioned in 2003 and is in operation since then continuously
for 300 days in a year.
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E.
F.
Average gross power generation per month: 24,000 kWh
Average auxiliary power consumption per month: 3,500 kWh
Average biomass consumption per month: 22,080 Kgs
Average diesel consumption per month: 792 Litres
Operating hours/day: 24 hours
Average specific diesel consumption: 0.033 litres/kWh
Cost of Production
The unit cost breakup of gross power generation is given in Figure 12 below.
Figure 12 Unit Generation Breakup Cost at VIT in %
30%
40%
27%
3%
Diesel Cost
Biomass Cost
AMC
Observations:
Diesel cost plays a vital role in power generation cost.
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Labour
ITCOT
Manpower is required for fuel sizing of non-processed wood. The salary for
operators (Totaling fourteen in number for 3 shifts operation) is around Rs.
60 per day per person.
G.
Repairs and maintenance cost is considered at 3% of the production cost
Summary of notes of discussion with VIT
About Fuel
Julia flora is the fuel used and the calorific value is around 3500 kCal/ kg
The size of the fuel is 1.5 inches in diameter and 3 inches in length
The moisture in the fuel is less than 15% at the feeding point of gasifier
Average replacement of diesel achieved 87 % (Max: 88% and Min: 70%)
Water Utilisation
The makeup water of 1000 litres is used for every two days.
Load Pattern
A section of hostel load is connected to the gasifier system and it provides a
fairly constant demand of 50~60 kW.
Waste Heat Recovery (WHR)

VIT has installed a WHR at engine exhaust for drying biomass with 1,600 kg of
drier holding capacity and it was informed as very effective.
H.
Issues
Gas cooling and filter systems for gas cleaning have been highlighted as the
problem prone area, which have been rectified by VIT themselves. However, the
technical details on the modifications carried out have not been disclosed.
VIT conveyed that overall performance of the gasifier was satisfactory.
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3.8
Name of Installation: Periyar Maniammai College of Technology for

Women
A.
Project Background
Objective
Periyar Maniammai College of Technology for Women (PMCTW) has installed 100
kW Dual Fuel Mode Gasifier system during 2001 and later installed 200 kW 100%
producer gas based Gasifier system during 2004. The college has installed the
gasifiers for captive consumption and for carrying out R&D activities in the field
of renewable energy.
The dual fuel based gasifier plant was installed during 2001 and the 100%
producer gas based plant was installed on 24th June 2004.
Location
Periyar Maniammai College of Technology for Women is located at Vallam, and is
accessible from Thanjavur by road at a distance of 20 Kms.
Plant lay out Size
5m X15m
Type
B.
The College has provided technical details for 200 kW system alone.
Gasifier (Supplier Ankur Scientific Energy Technologies Private
Limited, Baroda)
i) Capacity: 200 kW
ii) Biomass fuel consumption: 300 kg/h
iii) Moisture: < 20%
iv) Loading of biomass: Automatic
v) Gasifier starting: Manual
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vi) Gas cooling and cleaning of tar removal, particulates: Cyclone

Separator, 4 Nos. of active and passive coarse filters, fine filters
with sawdust.
vii) Gas flaring provision before engine entry
viii) Height of reactor 10 ft.
ix) Auxiliary power: 20 kW includes pumps in cooling tower, pumps in
gasifier, pumps in engine and blower
x) Recommended biomass fuels: Casuarinas, eucalyptus, Julia flora
and any hardwood
xi) Gasifier material of construction: Stainless Steel for nozzle and
throat and MS for Hopper, body and pipe line
xii) Life of Gasifier: 5 years
xiii) Turn down ratio: 30%
xiv) Starting time from cold start: 15 minutes
Engine (make - Cummins)
Model: GTA 1710 G
Starting system: Battery
KVA: 320, Speed rpm: 1500
Voltage: 415 V, Amps: 445 Ampere, Frequency, 50Hz
Power factor 0.8, Continuous rating
DC Excitation 38 V: 2 A, Star Connected, Enclosure: IP 23
Insulation: Class H
Electrical panels
The plant is designed to operate in stand-alone mode and the gasifier power is
fed to six changeover points in the college. The panel is provided with over
voltage, over current and over speed protection. The panel reads voltage,
current and energy online.
C.
Not Provided
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D.
Project Status
The plant was on run from July 2 2004 and is in operation without any trouble
since then. The plant operates for 12 to 14 hours a day for 6 days a week.
E.
Average Plant Performance
Gross Power Generation: 50,000 kWh per month
Auxiliary Power Consumption: 5,000 kWh per month
Total biomass consumption: 300 kgs per hour
Average
cost
of
gross
power
generation:
Rs.2.25/kWh
without
depreciation and interest on loan

F.
Overall Observations
Personnel required for loading the gasifier is eliminated in Ankur Scientific

System since lift is used for loading the Gasifier; as the manual operation is
not required, the cost of labour is only for processing the fuel; and hence,
taken as Rs.0.10 per kg of fuel used.
Repairs and maintenance cost is not considered, as the plant is new.
The gasifier system has an improved version when compared to Valli Chlorate
system (as it is the first gasifier) in gas distribution and governing.
The system is provided with gas controlled pneumatic systems.
Producer gas is fed into the engine through valve control and depending
upon the load, gas is provided with these valve controls.
G.
Summary of notes on discussion with PMCTW
PMCTW gasifier is of Ankur Scientific Make with Cummins engine of 200 kW

with a capital subsidy of Rs. 30 lakhs from MNES, New Delhi
There are 6 change over points (load points) connected to the gasifier.
Main building, computer building, Hostel 1, Hostel 2, Hospital and Farms are
the six load points
EB tariff for the college is Rs. 4.80 per kWh and for the farm alone is Rs. 6
per kWh.
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The gasifier fuel is Julia flora and Eucalyptus and fed at an interval of 2 hours
in its 14-hour operation, which is acquired through Self Help Groups (SHG)
and local villagers.
During each interval 240 kgs of wood is fed into the gasifier and the cost of
biomass is Rs. 1200 per ton.
Average unit generated is Rs. 50,000 units per month and the auxiliary
consumption is around 10% and the net export is Rs. 45,000 per month.
Auxiliary loads are as follows:

a. The water cooling system for gasifier is served with three pumps (2 x 3
HP + 1 x 2 HP) 7 HP
b. Water cooling system for engine with two pumps (1 x 3 HP and 1 x 2 HP)
5 HP
c. Engine Cooler Pumps 1 HP
d. Blower 12.5 HP
The live load pattern taken up from control panel on 11th April 2005 is as
follows:
a. Amps: 153 A
b. KW: 125 kW
c. Voltage: 414 V
d. Frequency: 49.5 to 50.4 Hz
H.
Issues
Since the college has been operating the system for the last two years, no major
issues were highlighted during discussion.
I.

There are no major reported issues though constant loading is a problem. The
college observed that, due to changing loads, it would not be possible for the
system to be synchronized with the grid, due to changing frequency.
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3.9
Name of Installation: G B Food Oils Private Limited, Pudupatty

G. B. Food Oils has installed a 1x100 kW Gasifier supplied by Netpro Renewable
Energy (India) Limited, Bangalore, Karnataka. The project is on a test run and
highlights of the system are detailed below:
Netpro Renewable Energy (India) Limited, Bangalore, Karnataka and G. B.

Food Oils Limited have 50 50 share in gasifier supply.
1 x 100 kW gasifier is installed in G. B. Food Oils, Pudupatty and 1 x 100 kW

gasifier is installed in GB Enterprises, Trichy.
These two gasifiers are test run gasifiers.
Gasifier at G. B. Food Oils is operated for 20 days in Dual Fuel Mode during
December 2003 connected to one 125-kVA engine. The energy generation
through engine was struck due to problems in engine and hence stopped
operating diesel engine.
The unit has two engines of 125 and 63 kVA and the total load of the unit is
400 HP. The unit is connected to HT line at the rate of Rs. 4.80 per unit.
The unit has ordered for Greaves 300 kVA LPG based engine modified to
100% producer gas engine for Rs. 16 lakhs and Rs. 10 lakhs grant was
agreed by MNES, New Delhi.
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CHAPTER 4
VENDOR CAPABILITY AND TECHNOLOGY PENETRATION
4.1
Vendors
There are only a few technology suppliers and manufacturers in India and to
obtain the status of technology and capability of Gasifier and Engine suppliers, a
detailed questionnaire was sent to the manufacturers of Gasifier systems for
their feed back on their capabilities and list of Installations. The vendor list as
follows:
Table 14
Vendors supplying Gasifiers
S. No
Name of the Gasifier Supplier/ Technology Provider
Netpro Renewable Energy (India) Limited, Bangalore, Karnataka
Ankur Scientific Energy Technologies Private Limited, Baroda
Energreen Power Limited, Chennai, Tamilnadu
Cosmo Powertech Private Limited, Raipur, Chhattisgarh
Centre for Gasification and Propulsion Laboratory (CGPL), Indian

Institute of Science, Bangalore, Karnataka
Grain Processing Industries (India) Private Limited, Kolkata, West

Bengal
Associated Engineering Works (AEW), Hyderabad, Andhra Pradesh
Out of the above Ankur, Grain Processing, AEW and Cosmo have their own
technologies, while the others use the technology developed by IISc.
The feed back from the manufacturers was poor in that only one vendor
responded with the filled in questionnaire, and ITCOT had one to one discussions
with the following vendors after receiving their concurrence
a. Ankur Scientific Energy Technologies private Limited, Regional office at
Kolkata
b. Netpro Renewable Energy (India) Limited, Bangalore, Karnataka
c. Grain Processing Industries (India) Private Limited, Kolkata, West Bengal
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4.1.1 Gasifier Type

All vendors supply downdraft gasifiers except Grain Processing Private Limited.
Woody biomass gasifier, fine biomass gasifier and gas based biomass gasifier are
the different types supplied by the vendors.
4.1.2 Vendor Capability on Capacity
Ankur Scientific Energy Technologies Ltd

The company is in operation for more than 15 years with many awards from
Research institutions and Government, and is one of the MNES approved
vendors.
They are having the manufacturing capability to produce gasifier
systems for both thermal and electrical applications based on both woody (WBG)
and fine biomass (FBG). The highlights of technical specifications are given
below as Table 15.
Table 15
Ankur Gasifier Technical Specifications
Parameters
FBG Series
WBG
Gasifier Modes
FBG-40, 60, 80, 100, 120, 150, WBG; 40, 60, 80, 100,
200, 250, 300, 335
120, 150, 205, 250, 300,

400, 500
Type
Down Draft
- do -
Size Min. & 2 mm on cylindrical diameter
D: 10 mm; L: 10 mm
Max.
Diameter: 3mm, L: 20 mm
Moisture
10% (max.)
< 20%
Gasification
900-100
1,050-1,100
Temp. C
Efficiency-
Hot 65 to 75
> 85%
Efficiency - Cold 60 to 65
> 75%
Gas mode
Gas mode
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ITCOT
The capability of the vendor in supplying the system as provided in the

questionnaire is given below as Table 16.
Table 16
Vendor capability in supplying the system
S. No
Type
Model
Capability
Woody Biomass
WBG-5 to WBG-850
Can manufacture at
Fine Biomass
FBG-40 to FBG-400
least 500 systems of
Combo
Combo-150 to 350
small
100% producer gas based Gas-4 to 425
another
power pack systems
systems of higher
ratings
and
300
ratings
NETPRO Renewable Energy (India) Pvt. Ltd. (NETPRO)
The company was established in 1994 to design and manufacture biomass
gasification plants in association with IISc, Bangalore and Dasag Energy
Engineering Ltd., Switzerland. NETPROs current focus is on large scale
Commercialisation of biomass gasification plants of various sizes for power
generation as well as thermal applications. Netpro has a technical collaboration
agreement with the Indian Institute of Science (IISc), Bangalore, India, a
premium-engineering institute of the country.
NETPRO undertakes the turnkey execution of power generation facilities with
unit capacities up to 500 kW and tailor made designs for thermal applications. It
has supplied a large number of gasifiers in India, USA, Switzerland and Kenya.
Table 17
Typical Technical Data of an IISc Netpro Biomass Gasification Plant
Parameter
Specification
Ratings of the Gasifier
25 kg/ h to 750 kg/ h of standard biomass
Type
Open top, down draft solid biomass gasifier
Feed Stock
Any solid biomass with bulk density over 200kg/m3,

moisture content less than 15% cut to a maximum
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ITCOT
size of 60 mm x 20 mm x 20 mm
Average Lower Calorific
4.5 + 0.2 Mj/ kg
Value
Typical gas composition (%
CO: 20 + 1%: CH4 : 3 + 1%, H2 : 20 + 1%, CO2 :
by volume)
12 + 1%; O2 : 0.1% (max) and rest N2.
Turndown ratio
4:1
(max./min.) load
Avg. specific weight of
1.12 kg/ Nm3
producer gas
Auxiliary plant loads
Water pump, Chiller, Suction blower, Chilled water

pump
Application
Diesel substitution upto 70 80% is expected to

be achieved in dual fuel mode of operation on
specified diesel engines at or above 75% of the
rated load. The tune to which diesel substitution
could be achieved is sensitive to the moisture
content in the biomass
Gas quantity with
Hot end
Cold end
standard biomass
Tar: 70 + 30 ppm
< 40 + 10 ppm
Particles: 600 + 100 ppm
< 30 + 10 ppm Tar
Gasification efficiency with
Hot gas: 80 85% Cold gas: >75% at high loads
standard biomass
Specific Wood Consumption Depends upon the engine. Typically, with biomass
of 12% moisture content: 1.1+0.1 kg/kWh in dual
fuel mode and 1.3 + 0.1 kg/ kWh in pure gas
mode.
Associated Engineering Works Ltd
The vendor is in operation for more than 10 years supplying gasifiers for both
thermal & electrical dual fuel applications. The typical technical specification of
models manufactured by the vendor as per the brochure is given below in Table
18.
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Table 18
Data Table - Associated Engineering Works
Electrical / Power Application
S.NO.
SPECIFICATIONS
Nominal Rated output to KCal/Hr.
Rated Electrical Output (kW)
Wood/ Biomass consumption in
MODEL
GE-350
50000
GE 450
GE 600
1,00,000 2,50,000
20
40
100
20
40
100
5-20%
5-20%
5-20%
100
200
500
1.5
1/2" - 1
3/4" - 1
length)
1/2"
1/2"
1" - 2"
Typical diesel replacement (Average)
65%
65%
65%
10
Floor space required
8'-8'
10'-15'
10'-20'
Kg./Hr.
4
Moisture content acceptable
Hopper holding capacity in Kgs.
Aux. Power required (HP)
Wood Cutter Motor H.P
Wood chip size range (Diameter or
Energreen Power Ltd, Chennai

The vendor is in operation for more than 5 years supplying Gasifiers system with
technical know how from IISC, Bangalore. Though no details are provided on
their capability or the current operation, based on the discussions, it was
observed the first 1 MW grid connected Gasifier has been supplied by the vendor
though no details could be obtained either from the vendor or from the promoter
M/s. Arasi Hi Tech Bio Power Pvt Ltd, Tamil Nadu.
Based on the secondary
survey it is noted that the vendor is capable of supplying the following systems
Thermal systems: 100kW to 10MW
Electrical systems: 20kWe to 2 MW
The technical specifications of the systems as per the claim of the vendor are
given below.
Specific fuel consumption for dual fuel mode: 0.8 to 0.9 kg of

biomass/kwh
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Diesel replacement possible for dual fuel mode: 80%
Specific fuel consumption for producer gas mode: 1.0 to 1.2 kg of

biomass/1kWh
Grain processing Industries (India) Pvt. Ltd.

The vendor is in operational for more than 10 years and the system design is
based on updraft and the various models available are given below in Table 19.
Table 19
Grain Processing Industries (India) Pvt. Ltd. Technical Specifications
Specifications
GP 100
Max. Electrical output (kW)
GP 200
GP 500
100
200
500
Max. Thermal Output (KCal./hr.)
2,50,000
5,00,000
12,50,000
Rated Biomass Consumption
2,50,000
5,00,000
12,50,000
40 x 40
50x40
50x60
(Kg./hr.) (Including 10-15% diesel

oil)
Min. space required for plant (Sq.
ft.)
Cosmo Power tech Pvt Ltd
The company is in the process of supplying Gasifier systems with dual fuel mode
and is one of the approved vendors of MNES and has supplied 500 kW dual fuel
mode gasifier systems.
4.1.3 Guarantee/Warrantee Provided

Though no guarantee is provided on the performance for the system as a whole
by these vendors as characteristics of standard biomass vary based on site
conditions, few vendors like Ankur, have provided guarantee to following
equipment supplied by them.
a. Gasifier
b. Burner
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c. Dual fuel engine

d. Cutters
e. Filters
f. Skip Charger
g. Wood Dryer
h. Variable Load Control System
4.1.4 Annual Maintenance Contract
Annual Maintenance Contract is provided to the equipment under guarantee.
4.2.
Engine
Various engine manufacturers have supplied engine for producing power from
the gas generated from the gasifiers. Engines specific to 100% producer gas
usage and with dual fuel option (usually Diesel) has been used for generating
power. The vendors supplying 100% producer gas engine and Dual Fuel Engine
for the gasifier system is detailed below.
4.2.1 100% Producer Gas Engine

Supply, Erection, Testing and Commissioning of 100% Producer gas engine has
been under the responsibility of Gasifier Suppliers / Vendors. So far for higher
capacity range the engine has been supplied by Cummins. Of the 14 installations
visited following are the systems with 100% producer gas engine.
Table 20
List of Installations with 100% Producer Gas Engine
NO.
Name of the
Engine
Alternator
Gasifier
Unit
make
Make
Supplier
PMCTW, Vallam
Cummins
Stamford
Ankur
VCC, Kovilpatti
Cummins
Stamford
Ankur
Nellithurai
Dipco
Compton
Ankur
replaced with Greaves

Field Marshall
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Odanthurai
Dipco
Crompton
Ankur
Greaves
5
Bagavathi
Bio, Cummins
Stamford
Energreen
Stamford
Netpro
Mettupalayam
6
PSG, Coimbatore
Cummins
4.2.2 Dual Fuel Engine

Supply, Erection, Testing and Commissioning of Dual Fuel Engine has been the
responsibility of Gasifier Suppliers / Vendors. Gasifier supplier provides the
Guarantee for the engines supplied. The engine for dual fuel mode has been
Kirloskar, Greaves, Ashok Leyland and Yanmar. Of the 14 installations visited
following are the systems with Dual Fuel Engine.
Table 21
List of Installations with Dual Fuel Engine
No.
1
Name of the Unit

MVIT, Bangalore
Engine
Alternator
Gasifier
make
Make
Supplier
Kirloskar
Kirloskar and Netpro
and Greaves
Stamford
VIT, Vellore
Netpro
Jagat Alloys, Khopoli
Yanmar
Taiyo
Cosmo
PMCTW, Vallam
Ashok
Kirloskar
AEW
Crompton
Ankur
Leyland
5
Gosaba Islands
Greaves
Greaves
6
Chotamulakalli
Greaves
Islands
7
8
Ashok
Engineering College
Leyland
B.
Ankur
Greaves
Pondicherry
G.
Crompton
Food
Oils NA
Private Limited
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Kirloskar
AEW
NA
Netpro
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4.3.
Technology Penetration
Gasifiers have started as a thermal application device and with further
improvements have been extended to electrical applications. Reasonable
technology developments have taken place especially in gas cleaning and cooling
system and in engines to use 100% producer for power generation.
4.4.
Improvement Required
Improvement in system performance could be further improved.
Gas Cleaning System

Gas Flow Controlling System
Engine Cooling System
4.5.
Research & Development

Indian institute of science, Bangalore is the only institute in India who have
developed laboratory models to commercialized gasifier systems in India and is
actively involved in research and development activities and some of the current
activities are given below
Gas Engine Adaptation
Systematic Procedure Experiments & Modeling
Testing of various capacity Engines 0.5 to 200 kWe ~ at varying CR
Design of gas circuitry elements ~ Gas Carburetor
Identify key parameters like the optimum ignition timing and establish
maximum rating in each case
Engines tested in the laboratory and in the field
Kirloskar Oil engine (RB 33) (converted from available diesel engine to gas
engine)
Greaves 250 kVA producer gas engine
Cummins G743G and GTA 855G
Test Summary
G 743G & GTA855G adapted for producer gas operations replacing

Natural gas carburetor with Producer gas carburetor
Engines tested at different ignition timings and optimum identified
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Tested for 75 hours at the laboratory; two 24 hour run active

participation from Cummins
Parameters monitored energy input, power output and emissions
Engine run smooth with clean gas admitted to the engine
No deposition found in the Throttle valve, Intake manifold & Cylindrical

Head
A peak load of 55 kWe (60 kW) recorded in PG against 84 kW in NG
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CHAPTER 5
BARRIERS TO GASIFIER PROGRAMME AND POLICY ISSUES
5.1.
Barrier Identification
Gasifier based power production is under development and has the following
barriers.
5.1.1 Biomass Resource Identification and Logistics in Collection

Ministry of Non Conventional Energy Sources has carried out Biomass Resource
Assessment study in four phases at Taluka level through National Biomass
Resource Assessment Program (NBRAP) with the help of National Focal Point,
Apex Institutions and Consultants. This has been carried out for taluka level and
further extended to the district level. This study, especially in South India focuses
on forest wood, agricultural field level residue, agro industries residue and the
wood traded around in the area concerned. The report gives a broad outline of
biomass availability in the area concerned.
However, this does not provide any clear indication of the biomass quantity and
availability at closer vicinity and at desired price suitable for gasifier operation.
The units however before putting up their individual gasifier unit should assess
the biomass required for operation.
Collecting the biomass from various sources requires better and controlled
logistics. The units in operation consume biomass from traders and brokers. If
the unit handles the collection of biomass themselves, they find it tough to
handle. However, if the biomass is purchased in open market, then the cost,
collection, handling of biomass becomes very sensitive to market changes, which
leads to high landing cost, poor quality of the purchased biomass and un
processed fuel for the gasifier.
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Site-specific conditions with respect to Biomass Resource Identification are

detailed below:
a. M. Vishveswaraiah Institute of Technology, Bangalore, Vellore
Institute of Technology, Vellore, PSG Institute of Technology,

Coimbatore and Periyar Maniammai College of Technology for
Women, Vallam have assessed the requirement of biomass at site and
purchase wood before processing from local traders at a feasible price. Thus,
these units do not have any barrier to biomass resource.
b. Valli Chlorate company, Kovilpatti is gifted with plenty of woody biomass
(as recommended by vendors) in and around the plant site and hence,
resource is not a constraint for smooth operation of the unit.
c. Bagavathi Bio Private Limited, Coimbatore has drafted an agreement
with the local traders for smooth supply of biomass to the unit and hence,
faces no barrier currently on biomass availability.
d. Gosaba Islands and Chotamulakalli Islands enjoy the benefits from
Government of West Bengal, as the fuel (both wood and diesel) is supplied by
the Government. However, if a private entity puts up a unit in these Islands,
then it would not be financially feasible if fuel is purchased. However, private
units would enjoy smooth operation when the wood is from the local Energy
Plantation.
e. Nellithurai Panchayat and Odanthurai Panchayat has a low capacity
gasifier installed and hence the biomass requirement is met through local
self-help groups.
f. Pondicherry Engineering College, Jagat Alloys Private Limited,
Khopoli and G. B. Food Oils Private Limited, Pudupatty currently does
not operate the gasifier units.
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5.1.2 Cost of Biomass

Biomass cost is a matter of concern before putting up the gasifier unit. The cost
of woody biomass at most of the installations visited was around Rs. 800 to Rs.
850 during the time of installation and has soared up to Rs. 1200 per ton
presently in a span of 2 to 3 years.
The cost is inclusive of
a. Processing the wood either at site or at source
b. Loading and unloading
c. Labour Charges
d. Moisture content in wood
Of the points mentioned above from a to d even if one changes it has a direct
impact on the cost of biomass.
If the cost escalates in a unrealistic manner, then the feasibility of the project
would be at stake. Cost of biomass at sites visited is listed below in Table 22.
Table 22
Cost of Biomass at Various Installations
Cost of Biomass in Rs. Per ton
S. No
Name of the Unit
During
Installation
Current Cost
MVIT, Bangalore
800
1,100
PMCTW, Vallam
NA
NA
PSG, Coimbatore
1,000
NA
Pondicherry Engineering College
1,100
NA
VIT, Vellore
1,200
1,400
Gosaba Islands
NA
NA
Chotamulakalli Islands
NA
NA
Valli Chlorate Company, Kovilpatti
800
1,200
Bagavathi Bio Energy Limited
800
1,200
10
Jagat Alloys Private Limited
1,200
NA
11
G. B. Food Oils Private Limited
NA
NA
12
Odanthurai Panchayat
NA
NA
13
Nellithurai Panchayat
NA
NA
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5.1.3 Choice of Fuel Restriction

Gasifiers installed in various units in southern India use predominantly hardwood
as fuel to the gasifier. Biomass other than woods like straw, stalks, sawdust, coir
pith are not used which are available in plenty.
5.1.4 Soaring Cost of Diesel in Dual Fuel Mode
The gasifier units in Dual Fuel Mode operation face the heat on the soaring price
of diesel. The units installed three years ago derived the feasibility based on
diesel price of Rs. 18 per litre which is currently at Rs. 30 per litre.
M. Vishveswaraiah Institute of Technology, Bangalore has signed a PPA

with Netpro Renewable, Bangalore on the purchase of Power at Rs. 5 per kWh
escalated with respect to increase in Diesel price. Current purchase price is Rs.
5.70 per KWhr. If this price exceeds KPTCL price of Rs. 6 per kWh, then the
college might opt for KPTCL power and might stop the gasifier operation.
Jagat Alloys Private Limited, Khopoli, Maharashtra has installed gasifier of

500 kW in dual fuel mode but stopped operation by 2002 due to internal financial
problems. Also the hike in Diesel price made the project not financially feasible.
Islands of Sunderbunds enjoy the fuel supply from Government of West

Bengal and hence the cost does not play a vital role as the entire project is for
the community development and for socio economic improvement of these
Islands.
Periyar Maniammai College of Technology for Women, Vallam currently

does not operate 100 kW dual fuel mode based gasifier and uses only 200 kW
100% producer gas based system for energy generation.
G. B. Food Oils Private Limited and Pondicherry Engineering College

currently does not operate the system.
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Vellore Institute of Technology (VIT), is effectively loading the system by

which diesel replacement is by 87% and hence faces no major problem at
present.
All the other units apart from the units mentioned above are 100% producer gas
engine systems, which does not require diesel for their operation.
5.1.5 Technology
Although technical feasibility is available for the gasifier-based systems, the
operational problems are found especially in gas cleaning and cooling system.
The technology adopted in filters used in gas cleaning system plays a crucial role
in gasifier operation. Currently coarse sand, fine sand, fabric filters and saw dust
is used in cleaning system. Also chiller based gas cooling has been introduced to
bring down dust and tar levels in the gas.
Cooling tower based Engine-Cooling and Gas-Cooling is costlier in operation. The
desired cooling is also not achieved in these systems.
Islands of Sunderbunds often faces problem in gas cleaning system. The
sawdust used in the filters restricts the flow of gas into engines thus increasing
the consumption of diesel.
M. Vishveswaraiah Institute of Technology, Bangalore, has opted for a
chiller based gas cooling system in their Second phase, which solves the problem
of dust and tar generation.
Valli Chlorate Company, Kovilpatti has shut the plant for four months in the
year 2004 due to high operational cost of cooling towers and has installed coil
based cooling system for engine to reduce cost.
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5.1.6 Delay in Disbursement of Loans and Subsidy

Many units currently has adopted gasifier based energy generation system not
only on the basis of adopting renewable energy technology but for availing
subsidies and soft loans from Government to generate energy at a cheaper rate.
If the delay in disbursement persists it might lead to a closure of the parent
company itself.
Jagat Alloys Private Limited (JAPL) is a classical example.
JAPL for setting up 2 x 500 kW gasifier based power generating system has
approached Consultant to prepare Detailed Project Report (DPR) for submitting
the same to MEDA, MNES and Development Credit bank limited. Central Financial
Assistance (CFA) of 40.80 lakhs was approved by MNES for the year 2000 01.
50% of 40.80 lakhs i.e. 20.40 lakhs was sent to MEDA from MNES for granting
the subsidy. JAPL has mobilized equity through shares for their plant expansion
& gasifier installation and arranged loans other than MNES subsidy through
Development Credit bank limited.
JAPL has installed 1 x 500 kW gasifier and received 50% grant from 20.40 lakhs
i.e., 10.20 lakhs from MEDA. JAPL has commissioned 1st Phase 500 kW and
provided Rs. 8 lakhs as advance to Gasifier Supplier Cosmo power tech for
installing second phase.
However, MNES has asked for bank guarantee from JAPL to pay the final 50%
for 1st Phase and as bank guarantee could not be provided by JAPL though
nationalized bank (as Development Credit bank were their bankers a non
Nationalized bank) the second payment got delayed. This has forced the
company into financial crunch. Further to it, MNES after installation has
requested for type certificate of Cosmo power tech gasifier, adding further delay
in receiving the subsidy.
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After receiving the type certificate, MNES has requested IIT Mumbai to provide
common performance report (CPR) on gasifier performance. During trial, the
replacement of diesel was 58%. The reason indicated for lesser diesel
replacement was the wetness prevailed in the biomass used as the trial was
taken during rainy season and hence CPR submitted by GARP, IIT was rejected
by MNES and added further delay. Then final trial run was conducted on 2nd April
2002 and diesel replacement was achieved around 71%.
MNES has sanctioned the remaining subsidy for 1st Phase; However JAPL has
given up 2nd Phase and requested MNES to cancel the second phase grant for
another 500 kW.
5.2.
Measures to overcome Barriers

Following are some of the measures to overcome the above said barriers.
a. Support from Central and State Governments from scratch to commissioning
of the project.
b. Timely disbursement of loans and grants for smooth functioning in the
commissioning of the project.
c. Approvals of 100% producer gas system alone to prevent diesel playing a
pivot role in the operation of entire system.
d. Better biomass resource assessment
e. Better logistics in biomass trading and handling
f. Technology improvement in Cooling and Cleaning Systems
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CHAPTER 6
CASE STUDIES ON SUCCESSFUL INSTALLATIONS
6.1
Name of Installation: Valli Chlorate Company, Kovilpatti, Tamilnadu
A.
Project Background
Objective
Valli Chlorate Company (VCC), Kovilpatti is in operation from 1989 for producing
potassium chlorate (Kclo3), a major chemical for making matchsticks. The
company has its own matchsticks making factory called Meenakshi Match factory
at Kovilpatti. The company earlier had a High Tension (HT) service connection
from Tamilnadu Electricity Board (TNEB) for a connected load of 500 kVA. The
company uses D.C. Power supply in their operation for producing Potassium
Chlorate. During 1999, when the cost of kWh increased to Rs. 4.20 per kWh,
VCC has decided to shutdown the operations of the potassium chlorate company.
The company disconnected the HT service connection. In the year 2003, the
company planned to use Gasifier and approached an engineering company in
Kerala to modify their DG set into dual fuel mode engine. With the direction of
the engineering company, VCC approached Ankur Scientific, Baroda and revised
the plan of setting up a duel fuel engine to set up 100% producer gas system.
The company thus set up the first 200 kW / 100% producer gas based Gasifier in
Tamilnadu. When the company resumed operation in 2003, it has acquired an LT
connection of 50 HP load for auxiliary consumption. The plant capacity is around
1 ton / day and based on the demand the current production is around 10 tons
per month.
The gasifier was installed on June 23, 2003
Plant layout and Size
Total area of 3,000 Square feet
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Location
Valli Chlorate Company is located in Uppathur Road, Ovanayakanpatti village,
Sattur Taluka, Virudhunagar District, Tamilnadu. The unit is accessible from
Tirunelveli by road at a distance of 80 Kms via Kovilpatti.
FIGURE 13 Lay out of Valli Chlorate Company
COIL
BASED
COOLER
ALTERNATOR
RECTIFIER
TRANSFORMER
CONTROL
PANEL
GAS CLEANING SYSTEM
CUTTING
MACHINES
ENTRANCE
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GASIFIER AND
COOLING
SYSTEM
ITCOT
Type
B.
Gasifier (supplier Ankur Scientific Energy Technologies Private
Limited, Baroda)
(i)
Capacity: 200 kW
(ii)
Biomass fuel consumption: 300 kg/h
(iii)
Moisture: < 20%
(iv)
Loading of biomass: Automatic using lift
(v)
(vi)
Gas cooling and cleaning of tar removal, particulates: Cyclone Separator,

4 Nos. of active and passive coarse filters, fine filters with sawdust.
(vii)
Gas flaring provision before engine entry
(viii)
(ix)
Auxiliary power: 20 kW includes pumps in cooling tower, pumps in

gasifier, pumps in engine and blower
(x)

any hardwood
(xi)

(xii)
(xiii)
Turn down ratio: 30%
(xiv)
Starting time from cold start: 15 minutes
Engine (make - Cummins)
Model: GTA 1710 G
Date of Manufacture 11/10/2001
S. No: 35020
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KVA: 320
Speed rpm, 1500
Voltage, 415 V
Load, 445 Ampere
Frequency, 50Hz
Power factor 0.8
Continuous rating
DC Excitation 38 V: 2 A
Star Connected
Enclosure: IP 23
Insulation: Class H
Rectifier Transformer
Make: Hind Rectifier (Bombay)
DC Volt 60 V Current 4000 A
Phase 3
Frequency 50 Hz
Tank 700 kgs
Resistance 2.099
Oil 900 kgs
Rating: Continuous
Input KVA: 307.22
Primary: Main 415 V 427.4 A
Secondary: 108 498 V 1156 x 2 A
Electrical panels
The plant is designed to operate in stand-alone mode and the power generated
from gasifier is fed to rectifier transformer for AC to DC Conversion. Electrical
control panel is provided with Oil Circuit Breaker (OCB) of 400/440 Volts and 400
A rating with built in protections of under voltage, over voltage, over current and
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earth fault protection. The company has an LT connection of 50 HP for supplying

auxiliary power for starting gasifier plant auxiliaries.
C.

The company had land area for gasifier installation and hence spent negligible
amount for installing gasifier.

Equity: Rs.18.00 lakhs
MNES subsidy: Rs. 30.00 lakhs

D.
Project Status
The plant was commissioned on June 23, 2003 and was in operation for 9
months till March 31 2004. Due to Generator Breakdown, the operation resumed
from July 2004. The high operational cost of cooling tower has forced the unit to
install coil based cooler for engine, for which the installation period was four
months from November 2004 to March 2005. The gasifier operation was
shutdown during this period. The plant has been functional since then.
E.

(5 months from July 2004 to October 2004 and March 2005)
Gross Power Generation 1,72,890 kWh
Auxiliary Power Consumption: 38,868 kWh
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Table 23
Performance of VCC for the period July 2004 to March 2005
Month
Date (Excl.
Units
Aux.
Oper
Biomass
Holidays
Generat
Cons.
ation
consumption
ed in
In
Hrs.
kgs.
KWh
kWh
From
To
July 04
12.704
31.07.04
25,040
5,008
138
37,560
Aug 04
2.8.04
31.8.04
40,480
8,070
220
60,870
Sep 04
1.9.04
30.9.04
36,000
7,200
200
54,720
Oct 04
1.10.04
31.10.04
27,300
5,450
151
41,500
Mar 05
1.3.05
31.03.05
44,070
13,140
248
67,710
172,890
38,868
957
262,360
TOTAL
FIGURE 14 VCC Gasifier Average Plant Load Factor and

100.00%
90.00%
90.72%
92.00%
90.00%
90.40%
88.85%
Percentage %
80.00%
70.00%
60.00%
50.00%
40.00%
30.00%
39.07%
38.64%
39.16%
38.65%
38.23%
20.00%
10.00%
0.00%
July 2004
August 2004
September
2004
October 2004
March 2005
Weeks
Avg PLF
Overall % Gasifier Conv Efficiency
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FIGURE 15 - VCC, Kovilpatti 1 x 200 kW Biomass Gasifier

Plant Performance Data 2002 to 2004
1.54
50000
1.54
44070
40000
40480
kg/kWh
35000
1.52
1.52
1.52
36000
30000
27300
1.51
25040
1.50
1.50
45000
25000
20000
1.50
15000
10000
1.49
5000
1.48
0
July 2004
August 2004 September October 2004 March 2005

2004
kg/kWh
Total Energy Generated in kWh
FIGURE 16 - Energy Generation and Consumption Details

at VCC, Kovilpatti
70000
60000
50000
40000
30000
20000
10000
0
Jul-04
Aug-04
Sep-04
Oct-04
Nov-04
Biomass Consumption in kgs
Dec-04
Jan-05
Feb-05
Auxiliary Consumption in kWh
81
Mar-05
kWh
1.53
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Observations:
It could be seen from Figure 14 and 15 that when the Plant Load Factor
(PLF) increases on 100% producer gas mode, the gasifier conversion
efficiency also increases and vice versa.
It could be seen from Fig.15 that at various energy generation levels fuel
consumption per kWh is 1.50 to 1.52 kg/kWh.
It could be seen from Figure 16 that Auxiliary consumption is almost the

same throughout the period of operation i.e. around 20%
F.
Cost of Production
The cost breakup cost of gross power generation is given below:
FIGURE 17 - Unit Generation - Breakup Cost in %
8%
92%
Fuel Cost
Labour Cost
Observations
Personnel required for loading the gasifier is eliminated in Ankur Scientific
System since lift is used for loading the Gasifier. As the manual operation is not
required, the cost of labour is only for processing the fuel and hence, taken as
Rs. 0.10 per kg of fuel used. Based on the discussion, the operator salary is Rs.
340 per day for 8-hour operation for 25 days a month and the annual salary is
around Rs. 8,500 per month.
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Repairs and maintenance cost is not considered as the plant is new and it was
conveyed that it is covered under 2 years equipment guarantee with the supplier
for replacement of defect items for the entire gasifier system
G.
Performance: Design Vs actual

Table 24
Design Vs Actual Performance of VCC, Kovilpatti
S. No
Performance indicator
Unit
Design
Actual
Average kW loading
KW
200
185
Average Specific Biomass Consumption
Kg/kWh
1.3
1.51
The design value is considered at 100 % loading and is compared with actual
performance in the monitored period. The loading in operation is lesser
compared to the design value and hence, the performance could not be better or
at par with design.
H.
Summary of notes of discussion with VCC
The company sells Potassium Chlorate at a rate of Rs. 36 per kg. The
production cost with EB Power Supply was around Rs. 34 to 35 per kg results
in a meager profit margin. Due to gasifier installation, the production cost of
Potassium chlorate has come down to Rs. 28 to Rs. 30. This has helped the
plant in improving their profits.
The power generated is used into their titanium cell chamber by converting it
to DC source by rectifier transformer.
The operation of the unit is for 8 hours a day and extends some times to 10
hours a day and six days a week.
Spares, consumables are provided by Ankur as and when required
No major problem reported apart from generator cooling system failure and
breakdowns
Water requirement is met from 36,000 litres common sump, from where
water is pumped to a 12,000 litres an individual sump for Gasifier operation
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The company has its own lorry with two sintex tanks of 300 litres capacity
each to supply water from their farm.
The charcoal generation from Gasifier is around 10% of biomass used in a

day and sold in 40 kg bags at Rs.60 per bag.
The other small particulate residue apart from charcoal is used as manure for
their farms.
I.
No tar is reported in the Ankur system
Issues
Since the company has been operating the system for the last two years, no
major issues was found during the operating period.
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6.2
Name of Installation: Gosaba Island, 24 Parganas District, West Bengal
A.
Project Background
Objective
West Bengal Renewable Energy Development Agency (WBREDA) in association
with MNES, Government of India, Sunderbunds Development Department, Forest
Department, and South 24 Parganas, Zilla Parisad installed a 500 kW (5 x 100
kW) capacity biomass based power plant at Gosaba Island of Sunderbunds
where it is almost impossible to extend the conventional power grid line. The
prime objective of this power plant is to provide socio economic improvement of
the local people in Gosaba Island.
The 500 kW woody biomass based power plant was commissioned in Gosaba on
20th June 1997.
Location
Gosaba is situated at a distance of about 120 Km. from Kolkata (100 Km by road
and the rest by water transport).
The nearest Rail Stations are Howrah &
Sealdah. Road Distance from Sealdah to Sonakhali is 107 Kms. and waterway
distance between Sonakhali and Gosaba is about 10 Kms. Diesel Engine driven
Launches/ Mechanized boats operate between Sonakhali & Gosaba and takes
about 60 meters to reach Gosaba from Sonakhali. Adjacent to Sir Hamiltons
Estate Geographical co-ordinates: Latitude: 22 12 N, Longitude: 88 48 N.
Plant lay out Size
2,000 sq. ft.
Type
Woody biomass down draft gasifier with batch feeding.
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B.
Gasifier (supplier Ankur Scientific Energy Technologies, Baroda)
i)
Model: AG 100
ii)
Capacity: 100 kW
iii)
Components of gasifier
Hopper
Reactor
Cyclone
Venturi Scrubber
Blower for Coarse filter
Fine filter
Safety Filter
iv)
Rated gas flow: 250 m3/h
v)
Average gas Calorific value: > 1,000 kCal/m3
vi)
Biomass fuel consumption: 80 ~ 100kg/h
vii)
Gasification temperature: 1050 ~ 1100 deg. C
viii)
Indicative gasification efficiency:

Hot gas mode: > 85%
Cold gas mode: > 75%
ix)
Temperature at gasifier outlet: 250 ~ 400 deg. C
x)
Biomass fuel size:

Minimum diameter 10 mm and length 10 mm
Maximum diameter 60 mm and length 75 mm
xi)
Moisture: < 20% on wet basis
xii)
xiii)
Loading of biomass: intermittent manual feeding for every hour
xiv)
Ash removal: Continuous through proprietary control and water seal
xv)
Gasifier starting: Through scrubber pump/blower
xvi)
Specific fuel consumption: 250 ml/kWh full diesel mode
xvii)
Indicative diesel replacement: average 65 ~ 75% depending on

operating load
xviii) Engine conversion efficiency: 25%
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xix)
Gas cooling and cleaning of tar removal, particulates: Venturi scrubber

with water re-circulation and ultra clean gas for power generation
mode through proprietary and fine filters
xx)
xxi)
xxii)
Auxiliary power: 8 kW
xxiii) Water circulation: 250 litres per minute.

xxiv) Recommended biomass fuels: Casuarina, eucalyptus, subabul, Neem,
xxv)

xxvi) Life of Gasifier: 5 years

xxvii) Turn down ratio: 30%
xxviii) Starting time from cold start: 30 minutes
xxix) Maximum permissible particulate: 50 mg/m3
xxx)
Typical producer gas composition (%)

CO=19 +/- 3%
N2 50%
CO2=10 +/- 3%
H2=18 +/- 2% CH4=up to 3%
Engine (make - Greaves)
Capacity 151 hp
Alternator (Make Crompton Greaves)

KVA: 125, Speed rpm: 1500
Voltage: 415 V, Load: 175 Ampere
Frequency: 50Hz
Power factor 0.8
Electrical Systems
Gosaba Island was an un-electrified village until this project has been
commissioned and the plant was designed to operate in stand alone mode for
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village electrification purpose, as extension of the conventional grid power is

impossible.
FIGURE 18 - Electrical Schematic Diagram of Gosaba Installation
Feeder 1
Feeder 2
415 V bus
Bus
coupler
DG sets 1,2,3,4 and 5

The power generated from the five DGs can be synchronized at the 415 V bus
for parallel operation through a bus coupler and is taken through feeders 1 and
2, with each having a step up transformer of 315 kVA for power distribution at
11 kV. The existing 11 kV distribution circuit is 14 km and 415 V distribution
circuit is 19 km. The 415 V distribution has 5 nos of 100 kVA, step down
transformers located at various load ends. During the discussion it was informed
that distribution loss has been estimated at 8%.
Electrical control panel of 1500 Ampere capacity rating and each DG set is
provided with Molded Case Circuit Breaker (MCCB) of 300 A rating with built in
protections of under voltage, over voltage, over current, earth fault protection
and reverse power protections. The synchronizing panel has synchroscope and
the operators do a check-synchronizing relay and synchronizing operation
manually.
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C.
Land: 3 acres
Building and civil works:
Fuel processing yard: 600 sq ft
Fuel storage yard: 2000 sq ft
Gasifier system with DG set: 2000 sq ft
Plant and machinery cost: Rs 85 lakhs
Cost for land, buildings, power evacuation, others: Rs 65 lakhs
Total project cost: Rs 150 lakhs
Source of funds:
75% of the project cost from MNES
25% of the project from West Bengal State Government
Power evacuation cost:
Cost for 11 kV distribution: Rs 2.5 lakhs/km
Cost for 415 V distribution: Rs 1.5 lakhs/km
D.
Project in brief
Gosaba Island is one of the important islands of Sunderbunds. It is located in
South 24 Parganas District. The island is approximately at a distance of 120 km
from Calcutta with 25 sq. km area and has a population of 25,000 people. Till
May 1997, Gosaba Island did not have any electricity. The entire area used to
become dark after sunset. The local people approached WBREDA in the year
1996 for the provision of electricity from renewable sources of energy,
considering the fact that conventional energy may never come to Gosaba Island
after crossing of large number of creeks and rivers. After a careful survey of the
area, WBREDA decided to set up a 500 kW gasifier based power plant at Gosaba
Island along with energy plantation in wasteland and formation of a rural energy
co-operative with local people.
This project is a fine example of co-operation between MNES, WBREDA,
Sunderbunds Development Department, South 24 Parganas Zilla Parisad and
West Bengal State Electricity Board. The main motive force behind co-ordination
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of various departments and completion of work on schedule is the continued

efforts of WBREDA.
E.
Consumers and Tariff structure

It was informed that around 1,065 consumers are availing the power supply
through gasifiers and are grouped as below:
Domestic: Rs.5.00/kWh
Commercial: Rs 5.50/kWh
Hospital: Rs.6.00/kWh
There are no charges towards deposit fees and the above are flat tariff charges
with no taxes charged from consumers. Around 95% of the customers are
coming under domestic group.
F.
Gosaba plant operation

Another very important aspect is that the power plant is being run by a local cooperative society, viz. Gosaba Rural Energy Co-operative Society, formed for this
purpose. The society comprises of consumers representatives, WBREDA, WSEB,
Sunderbunds Development Board, Forest co-operative department and from
Govt. of West Bengal. The entire operation and maintenance of the plant is the
responsibility of the Co-operative Society. WBREDA is responsible for providing
diesel, biomass, and revenue collection and in rendering necessary assistance in
repair, maintenance and other works from time to time. The salaries for the
operating staff are met from the revenue collection through the prevailing
consumer tariff and the balance of the revenue collection is paid to WBREDA,
which takes care of diesel and biomass supply.
WBREDA is providing all technical and resource backup to the society for running
the plant. The plant has been working smoothly since commissioning.
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Biomass Fuel:
Woody biomass available in Sunderbunds is arranged through the society and
following are the different woody fuels that are used in the plant with an average
calorific value at 20 % moisture levels.
Akash 3,400 kCal/kg
Shirish 3,300 kCal/kg
Eucalyptus 3,600 kCal/kg
Subabul 3000 kCal/kg
Mango 3,000 kCal/kg
It was informed that moisture level at the time of purchasing will be around 70%
and is dried at the site to reduce to 20% before feeding into gasifier.
Revenue:
WBREDA indicated that the income and expenditure of the plant for the year
2003-2004, is as follows.
Income: Rs 30 lakh
Expenditure: Rs 33 lakhs
Deficit: Rs 3 lakhs
Though the operating figure indicates a net deficit, the plant was
provided financial support from the West Bengal state government
along with the technical guidance from WBREDA. The project model is
aimed at providing a socio economic benefit to Gosaba and also
indirect benefit to the nearby islands.
Gosaba plant performance in August 1997 ~ March 1998
(Source WBREDA annual report -1996 ~1998)
The operation in that period was limited to 6 hrs/day, from 17.00 hrs to 23.00
hrs. Initial demand for power was very low at 60kW and within one year, it grew
sharply to 200 kW. The summary of performance is given below and is expected
to improve further with increase in demand:
Total energy generated in that period, 77,505 kWh
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Total diesel consumed, 10,174 litres
Average specific diesel consumption, 0.13 litre / kWh
Total biomass consumed, 68,482 kgs
Average specific biomass consumption kg/kWh: 0.90
Average diesel replacement - 47%
FIGURE 19 Gosaba 5 x 100 Gasifier Plant Performance data

August 1997-March 1998
14,000
1.20
1.14
12,485
1.13
12,000
1.00
11,337
0.91
9,974
10,515
10,000
10,480
0.80
0.80
0.84
8,415
0.60
7,180
0.76
0.77
8,000
7,119
6,000
0.40
4,000
0.20
0.16
0.15
0.13
0.14
0.12
2,000
0.13
0.12
January'98
February'98
0.12
0.00
August '97 September '97 October '97 November '97 December'97
litres/ kWh
kg/ kWh
March'98
Gosaba plant performance in March 1~22, 2005

The plant was operating with 3 gasifiers 1,3 and 5. Gasifiers 2 and 4 were under
replacement with new ones and hence, are not in operating condition. The
gasifiers 1, 3 and 5 were replaced with new gasifier system in 2002.
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kWh
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Present Operating mode:

The plant was feeding power to the consumers from 10.00 am to 12.00 pm (say
14 hrs/day). One DG set starts on diesel operating mode at 9.30 am with one
gasifier firing simultaneously with woody biomass, and after the gasifier
stabilization, producer gas is fed into the DG set and DG set is under dual fuel
mode from 10.00 am. One DG set operates till 4.30 pm and the second DG set
with gasifier under dual fuel starts and the third DG set with gasifier starts by
5.00 pm. Thus, three DG sets on dual fuel mode are operated. For meeting the
evening peak load, fourth DG set on diesel mode is started at 6.30 pm and goes
till 8.30 pm. From 8.30 pm to 12.00 pm, only two DG sets are operated.
The plant operating data for the period March 1~22, 2005 was collected from
the operators logbook and following curves were drawn for plant performance
assessment.
Observations:
In that period, three gasifiers and four DG sets were operated to meet the
load requirement
From the logbook, it was observed that maximum load in Ampere

recorded in a DG set was 150 A (rated 175 Ampere). Two DG sets were
operated in that range, while the third DG set with a load of 110 Ampere
and the fourth DG with a load of 80 Ampere, was operated in the evening.
The cost of power generation was highest in March 17, 2005 at Rs

8.82/kWh with an average loading of 252 kW and PLF of 63%. The reason
could be the operating problems in the gasifier due to filter choking.
Hence, more diesel was consumed to maintain the load.
Producer gas from a particular gasifier is used in one or more DG sets in

an operating day, by changing the feed of DG sets, time to time. Hence, it
is difficult to assess the performance of a particular gasifier with a
dedicated DG set, as there is a provision for providing gas from any
gasifier to any DG set by shuffling the flexible hose piping of gas feeding,
in
order
to
overcome
operating
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problems
in
DG
sets/gasifiers
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FIGURE 20 Gosaba Island 5 x100 KW March Operating Data
300
12
269
270
257
256
232
253
239
244
233
238
235
replacement
220
233
226
150
7.57
7.79
7.70
7.92
7.85
7.73
7.62
7.45
7.58
241
240
10
219
8.41
8.82
7.47
233
214
190
200
252
8.37
8.35
8.34
8.15
7.71
7.40
7.06
7.02
7.62
7.40
100
64
67
67
64
58
61
60
61
58
59
55
48
54
59
58
63
63
57
58
60
18
19
20
21
55
60
50
14
13
12
11
10
12
15
23
13
17
21
16
-1
-6
0
1
10
11
12
13
14
15
15
16
17
2
22
Days
-50
0
% Diesel Repl
Avg kW
Avg PLF
94
Power generation cost Rs/kWh
Power Generation Cost Rs/kWh
244
250
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The availability of only three gasifiers, imminent filter problems (it was
informed that Gasifier 3 has pending filter problem and hence, gasifier
loading has been compared to the other two) and highly fluctuating load
demand, resulted in a poor plant performance. The associated gasifier
problems on power generation have contributed to the high cost of power
generation.
It was informed that fluctuating load demand was the main attribute for
the poor performance of the gasifiers. The load points are predominantly
lighting
(domestic,
commercial,
street),
fans,
irrigation
pumping,
commercial establishments like education institutions and hospital. Before

this power plant, consumers were using SPV for lighting and fans.
Though three gasifiers were replaced with new gasifiers in 2002 (Gasifier
1,3 and 5), it was informed that gasifier three has still problems in the
coarse and fine filter, often leading to pressure build up and reduced flow
of producer gas. Other two also have intermittent problems related to
filters.
The following is the summary of plant performance during the observed

period:
o Total energy generated, 34,866 kWh (this value is summated value of
energy meters at two outgoing feeders with added 10% auxiliary
consumption. It was noted that energy meter for DG 2 was not
working and hence, addition of individual DG energy meters for
comparing with feeder energy meters was not possible)
o Total biomass consumed: 26,733 kgs
o Total Diesel consumed: 7,869 litres
o Average diesel replacement: 10%
o Average loading: 238 kW
o Average PLF: 60%
o Average cost of power generation: Rs 7.79/kWh
o Average Specific diesel consumption: 0.23 litre/kWh
o Average Specific biomass consumption: 0.77 kg/kWh
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G.
Power generation cost breakup

FIGURE 21 Sunderbunds Gasifiers Installations Gosaba 5 x 100 kW
Dual Fuel mode power generation cost breakup (Rs./kWh)
operator cost Rs/kwh,

0.24, 3%
Maintenance Cost
Rs/kwh, 0.11, 1%
Biomass cost Rs/kWh,

0.77, 10%
Diesel cost Rs/kWh,

6.77, 86%
Diesel cost Rs/kWh
Biomass cost Rs/kWh
operator cost Rs/kwh
Maintenance Cost Rs/kwh
86% of the power cost is due to diesel and it warrants immediate detailed
performance evaluation of the gasifier systems
10% of the power cost is due to biomass and is higher due to lower
replacement of diesel
Operator cost and maintenance cost is 3% and 1% respectively, which are

negligible compared to the fuel cost
List of assumptions on costing, based on the discussions:

)
Biomass fuel cost @ Rs1.00/kg
Diesel cost @ Rs 30/litre
20 operators for the plant @Rs 2500/operator/month

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H.
Annual maintenance cost/gasifier: Rs. 20,000
Annual maintenance cost of DG set: Rs 25,000
Performance Design Vs Actual

Table 25
Performance of Gosaba Installation - Design Vs Actual
S. No
1
Unit
Average kW loading
kW
Average Specific Biomass
Kg/kWh
consumption
Average Diesel consumption

Average % diesel
Design
Litre/kWh
Percentage
replacement
Actual
500
238
0.77
0.06
0.23
70
10
Observations:
The plant has consumed more diesel than the design value, and hence,
biomass consumption has been lower than the design value due to poor and
fluctuating load
The reasons for the poor performance are problems of gas cooling and gas
cleaning system, engine operating performance and moisture content of
biomass.
The situation demands a thorough study on load demand; operation

performance of gasifiers on a continuous basis, issues related to gas quality
and increased diesel consumption.
I.
Maintenance
It was informed that no specific Annual Maintenance Contract (AMC) has been
signed with vendors for gasifier and engine system.
)
Annual maintenance cost/gasifier: Rs. 20,000
Annual maintenance cost of DG set: Rs. 25,000
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The above is inclusive of vendor representative site visit fees,
consumables and spares

A nominal charge of Rs 1000/day is charged by the vendors for site
visit
WBREDA is inviting vendors to the site in case of problems faced by
the operator.
FIGURE 22 Gosaba 5 x 100 kW Biomass Gasifier Plant
Performance Design Vs Actual
1.2
Kg/kWh, 1
1
Kg/kWh, 0.77
0.8
0.6
0.4
Litre/kWh, 0.23
0.2
Litre/kWh, 0.06
0
Kg/kWh
Litre/kWh
Actual
Design
Following is the maintenance schedule for various systems, as informed by

WBREDA.
Engine
Checking of engine after 10,000 hours of operation
Checking of engine cylinder head, nozzle injectors after 4000 hours
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First filling of lube oil 35 litre and changing of lube oil after 250 hrs. Lube oil
grade SAE 15W40
Routine checkup for diesel filter, engine and alternator coupling
Battery system weekly once
Gasifier
Generation of charcoal in kgs
Water spraying nozzles for gas cooling
Water pump and blowers motors
Coarse and Fine filter - cleaning of dry wood dust choke once in a week
Fabric cloth in check filter cleaning once in a week
The life of the filter material is 5,000 hrs and could be reused after washing
and cleaning
WBREDA informed that the overall service rendered by vendors have been
satisfactory.
J.
GOSABA Energy plantation

There are large areas of foreshore land on the riverbanks of Sunderbunds in
West Bengal. This area in the whole of the Indian part of Sunderbunds is
estimated to be about 0.15 million hectares, out of which 50,000 hectares are
suitable for plantation.
Energy plantation in an area of about 71 hectares was made for supplying woody
biomass to the Gosaba power plant. About 71 hectares of plantation has been
made under the captive energy plantation scheme attached to 500 kW capacity,
Gosaba biomass based power plant. The growth of trees under the schemes
appears to be satisfactory.
Effects of Energy Plantation
The biomass gasifiers consume woody biomass, which must be replaced to
maintain ecological balance. The Gosaba Biomass based power plant has been
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planned in such a manner that the biomass produced by the captive energy
plantation will generate more than the quantity it consumes. So in the long run it
will have a positive impact on the environment and the same time result in
employment generation as mentioned below:
b. Mainly branches and twigs between and 2 will be used in the gasifier
and in most cases the main tree will not be affected much.
c. New plantations are being made to replenish the biomass consumed by
the machine and this quantity produced is much higher than that
consumed.
d. The new plantations are made for running the power plant, otherwise
these plantations would not have come up.
e. A number of people get employment for planting trees and for
maintenance of plantations linked to the power plant.
So, it has positive effect on the environment as well as on employment
generation. The energy plantations will have the following positive effects:
a. It will help generation of employment opportunities in rural area.
b. Impact on rainfall pattern
c. Prevention of soil erosion
d. Preservation of flora and fauna
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6.3
Name of Installation:
M Vishveswaraiah Institute of Technology,
A.
Project Background
Objective
M Vishveswaraiah Institute of Technology (MVIT) has sought the assistance of
Netpro Renewable Energy Private Limited, Bangalore to install a Dual Fuel
gasifier-based power plant in their college premises and to supply power to the
college. The cost of gasifier system, operation and maintenance and the other
costs involved are under the scope of Netpro, and MVIT has allocated the land
for installing the gasifier. The power Purchase agreement between them is for 10
years @ Rs. 5 per kWh escalating with hike in diesel price. Current purchasing
price of power by MVIT from Gasifier system is Rs. 5.60 per kWh while the
current Electricity Board rate is Rs. 6 per kWh. The college has installed two 100
kW gasifier systems in phase I and II.
The month and year of installation of two phases are as follows.
Phase I: June 2002
Phase II: November 2002
Location
MVIT is located in Hunusumaranahalli, via Yelanka an hour drive from Bangalore.
Plant lay out Size
A copy of plant layout drawing is enclosed in Enclosure I.
Type
Woody biomass down draft gasifier with batch feeding.
B.
Gasifier (supplier Netpro Renewable Energy Private Limited,
Bangalore)
ii
Capacity: 100 kW
iii
iv
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Moisture: < 15%
vi
vii
viii
Diesel replacement: average: 75 - 85%
ix

cooler, cyclone separator, scrubber, sand (coarse and fine) filter, fabric
filter, 6C output - water chiller
Gas flaring provision before gas entry into engine
xi
Height of reactor: 2.9m
xii

any hardwood
xiii

and SS 304 for Hopper, body and pipe line
xiv
xv
Turn down ratio: 1:3
xvi
Starting time from cold start: 15 - 30 minutes
xvii
Conversion Efficiency (Fuel to Producer Gas): 75%
xviii
Conversion Efficiency (Engine): 30%
xix
Auxiliary Consumption: 32 HP for pumps
Engine
Phase I
Make: Kirloskar
Capacity: 2 x 50 kW
Governor: Mechanical
Phase II
Make: Greaves
Capacity: 1 x 100 kW
Governor: Electronic
Alternator
Phase I
Make: Kirloskar
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Capacity: 2 x 62.5 kVA
Speed: 1500 rpm
Voltage: 415 V
Frequency: 50 Hz
Power Factor: 0.8
Insulation: Class H
Phase II
Make: Stamford
Capacity: 1 x 160 kVA
Speed: 1500 rpm
Voltage: 415 V
Frequency: 50 Hz
Power Factor: 0.8
Insulation: Class H
Electrical panels
The plant is designed to operate on stand-alone mode. Electrical control panel is
provided with 100 Amps MCCB for Phase I and with 250 Amps with Phase II. The
panel is provided with under voltage, over voltage, earth fault and over current
protection along with reverse power relay.
C.

The college has allotted land for installing gasifier.

50% Equity by Netpro Renewable Energy Private Limited
50% Grant from Dutch Government
Total Project cost: Not disclosed
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D.
Project Status
The plant was commissioned by November 2002 (both Phase I and Phase II) and
was in operation since then, for 6 and half days a week and all weeks in a year.
E.

(3 years from June 2002 to December 2004)
Gross Power Generation: 8,94,928 kWh
Auxiliary Power Consumption: 1,00,496 kWh
Total Diesel Consumption: 99,700 Litres
No. of Operating Hours: 16,680 hours
Average annual PLF: 21.07 %
Average specific diesel consumption: 0.11 litres/kWh
The plant performance for the period monitored with energy generation, auxiliary
consumption, operating hours, Biomass consumption and Diesel Consumption, is
given in Table 26 below.
Table 26
MVIT - Plant Performance
Year
Units
Aux.
Operat
Biomass
Diesel
Generated
Cons.
ion
consump
Consumption
KWh
In kWh
Hrs.
tion kgs.
in KL
2002
63,821
7,650
360
53,790
9,600
2003
393,874
43,580
8,160
410,000
44,100
2004
437,233
49,266
8,160
490,000
46,000
894,928
100,496
16,680
953,790
99,700
TOTAL
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FIGURE 23 - MVIT Gasifier Average Plant Load Factor and

35
32.53
30
31.94
31.41
Percentage %
26.79
24.86
25
20
15
11.56
10
5
0
2002
2003
Avg PLF
2004
Weeks
Overall % Gasifier Conv Efficiency
FIGURE 24 - MVIT, Bangalore - 2 x 100 kW biomass gasifier

plant Performance data - 2002 to 2004
1.20
1.12
400000
393874
0.84
0.80
350000
300000
0.60
250000
200000
0.40
0.20
150000
100000
63821
0.15042
0.11196
0.10521
0.00
50000
0
2002
litres/kWh
2003
kg/kWh
2004
105
kWh
450000
437233
1.04
1.00
500000
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FIGURE 25 - Energy Generation and Consumption Details of MVIT

490000
500000
450000
410000
400000
437233
393874
350000
300000
250000
200000
150000
100000
50000
0
53970 63821
9600
44100 43580
46000 49266
7650
2002
2003
2004
Biomass Consumption in kgs
Diesel Consumption in Litres
Auxiliary Consumption in kWh
Observations:
It could be seen from Figure 23 and 24 that when the Plant Load Factor
(PLF) increases on the dual fuel mode operation, the diesel consumption
gets reduced with more producer gas being taken in for energy generation.
It could be seen from Figure 25 that Auxiliary consumption is almost the

same throughout the period of operation i.e. 11%
When annual PLF increases from 11 to 26%, the diesel replacement also
increases from 66% to 78% for the observed period.
When the biomass consumption increased by 19% in the last two years the
diesel consumption has increased by 5% during the same period. This has
resulted in the generation cost almost to be the same throughout the
observation period even when the cost per litre of diesel has soared from
Rs. 18 to Rs. 30 per litre.
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F.
Cost of Production
The cost breakup for gross power generation per unit is given in Figure 26
below:
FIGURE 26 - Unit Generation Break up Cost in % at MVIT
58%
22%
20%
Diesel Cost
Biomass Cost
Labour Cost
Observations:
Diesel Cost plays a vital role in unit cost of generation. In the PPA, MVIT and
Netpro have worked out a formula for escalation in purchase price based on
hike in Diesel price. The price of diesel at the time of installation was around
Rs. 18 per litre. Currently it is more than Rs. 30 per litre at site. Manpower
requirement is mainly for non-processed wood. The salary for operators
(Seven in Number) is around Rs. 2 to 3 lakhs a year and for a supervisor it is
around Rs. 0.72 to 0.84 lakhs a year.
G.
Repairs and maintenance cost is not considered as Netpro runs the plant.
Performance: Design Vs Actual

The design and actual performance comparison is detailed in the Table 27
below:
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Table 27
Design Vs Actual Performance of MVIT
No
1
2
Unit
Average kW loading
KW
200
185
Kg/kWh
1.1
1.065
Average Specific Biomass

consumption
Design
Actual
Observations:
Actual kW loading and specific Biomass Consumption are closer to Design
parameters. All other actual parameters are also in line with design parameters.
H.
Summary of notes on discussion with MVIT
About Gasifier
Gasifier installed in Phase II is an improved version of Phase I.
Cyclone separator and chilled water spraying system have been introduced in
the new version.
The new phase has cyclone separators before water spraying, to reduce tar
component in the gas. Chiller unit is provided to introduce water spraying at
6C before fabric filter to further reduce tar and dust content levels.
About Fuel
80 tons of wet Biomass is purchased every month and after drying 50 tons of
dry biomass is used in the Gasifier
Size of biomass used is 25 x 40 x 40 or 20 x 50 x 40 mm
Feeding on the open top is for every 5 minutes minimum and every 15
minutes maximum
3000 to 4000 litres of diesel is used per month replacing 20-25% of biomass
in the DG Set
Average Replacement of Diesel 81 % (Max: 85% and Min: 70%)
Waste Heat from DG set is used to dry biomass before feeding into gasifier.
About Energy Generation
50,000 to 52,000 kWh is generated from gasifier system and 45,000 kWh
(net) is exported to MVIT every month
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Current Energy Selling Price to college is Rs. 5.60 per kWh
Commercial tariff of KPTCL for the institution is Rs. 6.00 per kWh
Water Utilisation
Water consumption is through the sump of 50,000 litres capacity
The sump is cleaned every month and raw water of 50,000 litres is filled in
the tank.
10 loads of water per month are purchased of 6000 litres per load.
The makeup water of 1000 litres is used for every two days.
Water treatment is done while adding the make up water.
The chemicals used every 1000 litres make up water are

o Non Ferric Alum 400 grams and
o Poly electrolyte 20 grams
Load Pattern
Load sharing details are as follows:

o 86% of the college load is met by gasifiers
o 6% by the local DG Set of 30, 20, 10 kVA each
o 8% of the load is met from KPTCL Supply
I.
Issues
Since the supplier is operating the gasifiers, no major issues were highlighted
during discussion.
J.

It was observed that if the diesel price further hikes up, and if the generation
cost using gasifier in dual fuel mode moves above Rs. 6 per kWh, then the
college might opt for power supply from Karnataka Power Transmission
Company Limited (KPTCL) forcing the project to close.
k.
Overall performance
Netpro is presently successful in providing captive power to the college to the
greatest satisfaction.
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6.4
Name of Installation: Bagavathi Bio Power Limited, Mettupalayam
A.
Project background
M/s. Bagavathi Bio Power is a company, which was formed with the main aim of
generating power from Biomass through gasification and selling the same. A
company was formed and an agreement was made with M/s. United Bleachers
Limited for power purchase and M/s. Bagavathi Bio power will provide the plant
and machinery.
The contract is to supply 250kW/hr. First phase of 120kW/hr plant has been
commissioned and the plant has successfully completed six thousand eight
hundred hours of operation. The technology provider is IISC Bangalore and the
manufacturer is M/s. Energreen Power Ltd, Chennai. The gas engine used is
from Cummins. The engine is 855 GTA coupled with Stanford Alternator. The
maximum engine capacity is 130kW.After internal consumption of 23 kW for the
various plant auxiliaries; 100kW is ready for export to the textile-processing unit.
The plant operates continuously and generates around two thousand units per
day for export. The plant operates for around 26 days in a month. If the load is
constant then the plant operates in a trouble free manner
B.
Plant performance summary: 26th July, 2003 to 15th March 2005

The data on the performance of the project from the commencement of the
project was collected and given as Enclosure and based on the analysis, the
highlights of the project performance are given below.
Table 28
Plant Performance of Bagavathi Bio
S. No Parameter
Unit
Total no of days
Total
Value
532
Biomass
consumption
110
Tons
753.29
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Table 28 Contd..
S. No Parameter
3
Unit
Total
power
Value
Lakh kWh
6.36
Lakh kWh
4.55
Hours
6895
Hours
6637
generation
4
Power exported
Total
gasifier
operated hours
6
Total
Engine
operated hours
Based on the above performance, analysis on specific fuel consumption, plant

load factor etc were estimated and highlights of the performance are given
below.
Table 29
Plant Generation and Consumption Details
No
1
Parameter
Unit
Value
Average specific biomass
Kg/kWh
1.2
consumption
2
Auxiliary Power consumption
28
Availability of Gasifier on total
54
Availability of generator on %
52
days
4
total days
5
PLF
based
on
generator %
78
PLF based on total availability %
46
availability
6
days
The above table indicates the following
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The average specific biomass consumption is 1.2 kg/kWh, which is higher

than the design value, which may be due to low plant load factor.
The auxiliary power consumption is higher, which may be due to higher

installed capacity of the auxiliary equipments, which originally was planned
for higher capacity
Though the plant load factor of the system was 78% based on the actual
available days of generator, the PLF on total days is only 46%, which may be
due to down time of the engine /gasifier system
The performance of the system indicating specific biomass consumption and PLF
is given below.
Figure 27 Performance of Bagavathi Bio Energy
Plan
t
load
facto
r
100
2.00
90
1.80
80
1.60
70
1.40 Specific energy

consumption
60
1.20
50
1.00
40
0.80
30
0.60
20
PLF
Specific biomass consumption
10
0
0.20
Operating period
Note: Each operating period is period run before gasifier un loading
C.
0.40
Cost of production
The cost of production is as follows.
112
0.00
ITCOT
1.2 kg of Biomass gives 1 unit of electricity. Assuming raw material cost at

Rs1200/tonne, Cost of processing at Rs 300 per ton- Rs.1500 is the net cost
of raw material.
The plant requires three people per shift and one technical supervisor. The
engine is serviced at every 750hrs of operation.
Table 30
Cost of Production at Bagavathi Bio Energy Limited
S. No
Parameter
Cost/unitRs/kWh
Raw material cost per unit
1.80
Labour and Salary
0.35
Maintenance and Repairs
0.35
Net cost before interest and depreciation
2.50
The above breakup of the cost of production is depicted in a graph shown below.
FIGURE 28 Cost of Production at Bagavathi Bio Limited
113
ITCOT
The cost of production indicates that the raw material contributes 68% of the
cost and the unit is planning for its own cultivation to optimize the raw material
cost to around Rs.800 /ton.
D.
Issues relating to the performance
The plant will be operating continuously for a period of 25 days and the plant
load drops due to carbon deposit in the after cooler of engine. So stopping of
engine is required for cleaning and maintenance.
As the power is being exported to UBL, the plant will not be operating during
Sundays and also during plant breakdown of UBL, which will be around 2-3
days in a month.
It is observed that the load of the system is highly fluctuating based on

process requirement like intermittent operation of giggers and FD fans of
Boiler which lead to starving or excess load throw in the engine.
114
ITCOT
CHAPTER 7
CONCLUSION
Gasifier based Power Generating systems are technically feasible and

financially more viable, when run on 100% producer gas mode and not on
Dual Fuel Mode.
The project would be more successful if the availability and cost of biomass
used in the system are kept at constant check. Energy Plantation would be
the most feasible and reliable option for adequate and cheaper biomass
availability.
Constant Load operation and increased Plant Load Factor (PLF) would further
improve the financial viability of the Project.
Grid interfacing using gasifiers is very difficult and may not be possible as the
synchronization of grid frequency and the system frequency is not possible.
This is because of uneven flow of gas from the gasifier into the engine.
Technology available for gasifiers is satisfactory but not adequate. However,

further improvement in Gas Cooling, Cleaning, Ash removal, and Engine
Cooling Systems would increase the system availability and improve the
overall performance of the system.
Vendors currently do not provide overall performance guarantee to the

system as a whole though some vendors are providing guarantee to some of
the components manufacturers are having tie up with engine manufacturers
who are yet to provide performance guarantee for their engines with 100 %
producer gas applications.
Though IISC is the sole technology developer and provided solutions for the
operational problems of the gasifiers to a limited extend, most of the
115
ITCOT
developments /improvements in the field were carried out by the users only
and there is no agency involved in monitoring the performance on a
continuous basis.
The concept of Annual Maintenance contract is yet to be operational in the

market and after sales service or service back up by the vendors is very
limited as not many vendors are active in this field.
Well-trained technical manpower is limited in the market, which may affect

the sustained performance of the system.
Though most of the units are supportive of the capital subsidy scheme,
procedural delays from submission to actual disbursement of subsidy have
extended the time schedule of project implementation.
116

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ITCOT

Performance Of Ten Select Gasifier

Vendor Capability And Technology

Barriers To Gasifier Programme And

Case Studies Of Successful Installations

Letters from BERI

List of State Nodal Agencies Contacted

List of Vendors Contacted

List of installation visited

Design Vs Actual Performance (PEC)

Project Cost of Chottomollakhali

Three Year Performance of

Total Project Cost of PSG College

Operation & Manual Parameters of PSG

Actual operation of PSG College of

Technology Gasifier System

Performance during April 04 March 05

Cost of Energy Generation at Odanthurai

Nellithurai Plant Performance during

August 2004 to March 2005

Vendors Supplying Gasifiers

Ankur Gasifier Technical Specifications

Vendor Capability in supplying the system

Typical Technical Data of an IISc.- Netpro

Biomass Gasification Plant

Data Table Associated Engineering

Electrical / Power Application

Grain Processing Industries (India) Pvt.

Ltd. Technical Specifications

List of Installations with 100% Producer

List of Installations with Dual Fuel Engine

Cost of Biomass at Various Installations

Performance of VCC for the period July

2004 to March 2005

Design Vs. Actual Performance of VCC,

Performance of Gosaba Installation

Design Vs. Actual

MVIT Plant Performance

Design Vs. Actual Performance of MVIT

Plant Performance of Bagavathi Bio

Plant Generation and Consumption Details

Cost of Production at Bagavathi Bio

Detailed list of gasifier collected along with vendor

Site visit details

Copy of plant layout drawing of MVIT

Performance Data of Odanthurai Panchayat

Performance Data of Bagavathy Bio Power Ltd.

BIOMASS STORAGE YARD AT MVIT, BANGALORE

BIOMASS PROCESSING SHED AT MVIT, BANGALORE

GASIFIERS INSTALLED IN CHOTUMULAKHALLI

200 kW BIOMASS GASIFICATION PLANT LAYOUT IN PMCTW,

STORAGE YARD AT VALLI CHLORATE COMPANY, KOVILPATTI

100% PRODUCER GAS BASED CUMMINS ENGINE AT VCC,

DISCUSSION WITH MEDA OFFICIAL, PUNE, MAHARASHTRA

1 X 500 GASIFIER INSTALLATION AT JAGAT ALLOYS PVT.

PEC Gasifier Performance Analysis

PEC Specific Fuel Consumption Vs Gasifier

PEC Gasifier Dual Fuel mode Power

Generation Cost Breakup

PEC Performance Comparison Design Vs

Electrical Schematic Diagram of

PSG College of Technology Performance