MANUFACTURE OF PRODUCER GAS

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

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

PART 1

SOLID BIO-RESIDUE GASIFIER SYSTEM

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

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

in a device called gasifier in a limited supply of air. The clean combustible gas is combusted in a burner to generate heat. In the reactor the biomass process after undergoing drying in the upper zones leaving behind char. The volatilities undergoes oxidation in the combustion zone with air being partially supplied in the surrounding nozzles and the remaining drawn from the open top. The product gases of oxidation further gets reduced by a bed of charcoal and yield a combustible gases having a calorific value of 4.5-5 MJ/KG with an average composition of CO-20%, CH4-4%, H2-20%,CO2-12% and rest N2.

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

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

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

3.1 REACTOR The reactor is basically mild steel fabricated shell with insulated lining and has an inner lining of ceramic , compose largely of alumina . There are 2 sets of nozzles (provided around combustion zone) which are kept open during the operation of the system. The individual air nozzles are provided with a water seal which are kept open during the operation and closed to shut down respectively . There are ignition ports provided below the air nozzles for torching the reactor ( to start the reactor ) , water seals are provided with pneumatic valves which drain out water during initial starter and fills water into the seals during emergency situations. This arrangement is separate for 2 sets of air nozzles in corporated.

A water seals forms the top of the reactor with a removable cover. This cover is kept open during the entire operation of the system to facilitate loading of chips and the air being drawn from the top, there is a motorized screw at the bottom to extract the char . The char outlet is into a stainless steel fabricated container. The container has a capacity to hold approximately 1 shift discharge from the system. The screw system is decided by the set of timers both for frequency of operation and duration. The container provided has pneumatic valves. Under normal operation top valve is kept open and bottom is closed .The switch provided will result in top valve closing and the bottom opening to unload the char collected in container. The system also has a provision to

keep both the valves open for maintenance and during system shutdown both valves are closed. The system has necessary safety intelocks and alarms for improper usage . The screw is cooled both internally and externally for which cooling tower is employed.

3.2 COOLING AND CLEANING TOWER CYCLONE: The hot dust laden gas that exits the reactor is passed through a hot cyclone . Cyclone does the function of removal of certain quantity of solid particles . The dust that gets separated falls into a collection bin below and thus needs to be emptied periodically. COOLING SYSTEM: Twin H2O spray stations are employed with spray from top. The spray is developed from a jet which mixes with the gas and cools the gas to the ambient temperature and in process removes dust and tar. There is a small dump provided at the bottom which form exit for the cooler for separating gas and H2O gets collected in the H20 seal and

overflows by gravity to a sump,moisture trap is provided at exit of the scrubber to remove the H2O particles in gas . FLARE This is provided to check the initial quality of the combustible gas. Gas is flared in the burner for few minutes prior to changeover to drier .It is an automatic operational system.

LOADING OF CHARCOAL The reactor is loaded with dry charcoal, preferably till the top or 1m above the air nozzle level. The size of charcoal to be loaded is around 40mm*40mm*50mm. Care is taken to allow only charcoal which is free of metal pieces, plastic etc. FEED STOCK REQUIREMENT The range of biomass that can be used in the reactor as feed stock are coconut shells without fibre, different species of wood whose density is above 300350kg/m^3. The maximum moisture content should be around 12-15 %.

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

9.After successfully torching the reactor close the ignition ports. Open the air nozzle plugs to allow air entry through the air nozzle in the reactor. 10. Light the gas in the flare once the oxygen level falls below 2% the gas. Start-up diffusion mode typically within the reactor. 11. Top the biomass chips in the reactor as they undergo mixing thoroughly at regular intervals of time depending upon the consumption of feed time has to be set manually. Normally the consumption or time period is 10-20 minutes. 12. System has to operate on flare mode for more than half an hour for stabilization and to ensure gas of good quality.

RUN MODE 1.Manually push the button and energize the run mode. 2.At-least one of the drier local pumps switch needs to be on. 3.All the drier panels should not be under flame condition simultaneously. 4.Open main gas feed valve. 5.Close the flame line valve. STOP MODE Manually switch is in the stop mode energizing. This system is already in emergency mode. 1.Switch off the cooling tower. 2.Close the flare line valve.

SCREW OPERATION MODE Though the manual switch energizes the cyclic timer this can take place when main gas valve is open in auto mode or manual inch mode to operate the screw interlocks and the top valve should be open, ash discharged bottom valve should be closed and screw choking pump should be on. A separate switch for unload is provided which can be operated by authorised personnel. In closed mode screw motor can be switched on with interlock of ash discharge top valve and ash discharge bottom valve both being open.

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

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

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

OPERATION AND MAINTAINANCE

DRIER OPERATION 1. Start the drier with fuel oil combustion. 2. Once it is ensured that the gasifier operation is satisfactory and gas generated is combustible, feed the gas only when oxygen level drops below 2%. 3. To start the gas feed into dries, close the flare line valve manually and push the switch into run mode by which flare line valves closes and main gas line opens. 4. Use the valve near the burner and blower to control the quantity of gas flow. Reduce the oil flow while increasing gas flow. Airflow has to be controlled by using BUTTERFLY valve. 5. Always divert gas into the drier when oil flame is on. 6. Once the gas flow starts manometer indicates positive pressure. 7. Do not switch off the combustion blower in case of flame failure. This is the only way to remove the gas inside the drier. 8. Set the PID controller at desired temperature.

9. Flame failure is indicated with the help of thermocouple and controller within 15 seconds of flame failure. 10. Gas feed to drier will cut off and flare line will open in the following cases. 1.Power failure 2.Flame failure

MONITORING THE SYSTEM The normal and proper working of gasifier is ensured by visual inspecton of air nozzle. Continuos flow of biomass is a good sign of normal gasification process with the generation of good quality of air. For a given flow rate sudden or abnormal increase in pressure indicates the buildup of ash. This situation is temporary and can be eliminated by installing screw conveyors for few seconds until pressure comes back to normal. ASH EXTRACTION The screw provided needed to be operated periodically to remove ash formed in the reactor during gasification process.. this is required to keep pressure drop within limits therby allowing trouble free operation.

SHUT DOWN OF OPERATION During shut down following process must be followed. 1. Switch off the blower if in operation and close the main gas valve and open flare bypass valve. 2. Immediately ignite the gas. 3. Top the biomass chips in the reator. 4. Close air nozzle valves, this closes air entry into reactor. 5. Allow the fumes to come out of the reactor top. 6. Switch off the pump if in operation. 7. Switch off the instrumentation and panel.

MALFUNCTIONING AND TROUBLE SHOOTING It is important to know the reasons for malfunctioning of reactor. These may be the following reasons. 1. There could be air leakages into gasifier, resulting in dilution of producer gas .this leakage can occur at reactor or cooling tower. 2. There can be blockages in the reactor or in the cooling and cleaning section, causing resistance to gas flow. Total pressure drop should not exceed 300-350mm at full load operation.

MAINTAINANCE OF SYSTEM GASIFIER SECTION REACTOR 1. Rotate ash conveying screw one turn before start up for ash removal. 2. Unload the reactor once the pressure drops exceed the limit or else unload the ash every 1200hrs. 3. The collection of bin below the cyclone has a volume of 25lts and needs to be emptied every 8hrs.this operation is performed without shutting down the gasifier. 4. Extract solid residue from the screw exit water after each screw operation. 5. Tighten the bolts and nuts after the first 25 minutes of run.

COOLING AND CLEANING SYSTEM COOLER 1. Clean the cooler sprays and check the spray pattern once every 150 hours of run. 2. Clean the water dump seal-off the solid residues once every 150 hours of run or during any schedule weekly shutdowns. 3. Tighten all the bolts and nuts after the first 25 hours of run. VALVES AND BLOWERS 1. Clean the control valves pipelines and blower every 150hours run. 2. Lubricate the bearings of the blower and change the gland once every 600hours of operation, use lithium soap based grease.

WATER PUMP 1. Check the foot valve strainer every 150 hours of operation. Clear off any dust collected on it. WATER UNDER CIRCULATION 1. Every week slowly add 40 grams of poly electrolyte in both the tanks and using the valves keep the water under circulation. 2. Add 500grams of ALUM in both the tanks and using valves kee the water under circulation. 3. Keep the circulation ON for 30 minutes. 4. Allow the water to settle for 1 hour. 5. Repeat the above procedures several times depending on usage and biomass used during the week. 6. Drain the water slowly through sand and activated carbon.

LEAK TEST AFTER ASSEMBLY The entire gasifier has to qualify a leak test, which is one of the most important event in the erection of system. Critical subassemblies like the reactor and ash extraction system, cooler, cyclone have to qualify the leak test. However an entire system must undergo a leak test at all the flange joints after the erection at site. This has to be done in order to ensure that air doesnt leak into the system and dilute the producer gas. To conduct this test connect a pressure link which supplies air at a pressure of 100-150mm H2O to the exit duct-in from the blower ,that is prior to the duct-in connected to the flare. Fill the water seals of reactor, cooler , water dump and cyclone with adequate water upto overflow level. Further cover the top cover of reactor and fill the top cover water seal with water. Next, open the pressure line and apply soap water at all possible flange joints.

Incase there is leak, bubbles will form at all those points. Ensure all the possible leaks are pluged properly. In a similar manner conduct leakage test at all the duct-ins that leads to the burner. The leak test, is to be conducted every time whenever the system is dismantled for any form of maintainance. CHECK FOR AIR LEAKAGE GASIFIER IN COLD CONDITION-PRESSURISED MODE 1. Light a wick . Blow off the flame and hold the extinguished wick near to all possible points for leakage, like the flanged joints and pipe joints. Incase there is a leak, there will be tendency for the flame to be drawn inwards or sucked, indicating the leaking point. 2. Mend all leaks found. 3. The leakage of air could also be due to insufficient water in the water fills under

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

7. Reactor is loaded with biomass during the operation at regular time intervals depending upon the consumption. 8. There are no voids or gaps in the reactor by absorbing through the air nozzle. DONTS DO NOT 1. Pour water into the reactor under any circumstance to shut down the reactor. 2. Use larger sized and wet biomass other than specified. 3. Expose the bottom of reactor to atmosphere when the reactor is hot. 4. Operate the gasifier at higher load/flow rate immediately after fresh start, if done there is a possibility of biomass not totally converting into char by the time it reaches the air nozzle. Hence follow start up procedure meticulously. 5. Extract more charcoal.

UNLOADING THE REACTOR AND PROCEDURE FOR REACTOR REPAIR The reactor has to be unloaded once the pressure drop across the reactor shoots beyond 350mm H2O or else as mentioned in the maintainance schedule. It is better to leave the system unoperated for sufficiently long time, say a day so that the reactor bed cools down and makes the process of unloading easier. Firstly the ash extraction system supports bolts has to be lowered till it touches the ground and then should be secured tightly. The support bolts has to loosened until the wheels touch the ground. Use water to cool the unloaded hot charcoal pieces, if this is not done then there might be chances of fire hazard. The screw once removed needs to be closely examined for any erosion or damages. Check the metallic braded

graphite gland rope before refitting , if it is too compressed then it has to be changed. DAILY CHECK 1. Level in all water seals. 2. Drain blower bottom valve. 3. Clean cyclone bottom ash bin. 4. Clean ash extraction system outlet duct . 5. Ensure all valves are closed and no air gets into system during operation.