DE-31 (DME)

NUST COLLEGE OF
ELECTRICAL AND MECHANICAL ENGINEERING

DESIGN AND FABRICATION OF WOOD

GASIFICATION PLANT THAT RUNS A 15 KVA
STATIC LOAD GENERATOR

PROJECT REPORT
DE-31 (DME)
Submitted by

GC-UMAIR SAEED
PC-M.ADIL NASEER
BACHELORS
IN
MECHANICAL ENGINEERING
YEAR
2013
PROJECT SUPERVISOR
Dr AAMER AHMAD BAQAI

YEAR 2013

COLLEGE OF
ELECTRICAL AND MECHANICAL ENGINEERING
PESHAWAR ROAD, RAWALPINDI

DECLARATION
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been submitted in support of an application for another degree or qualification of this of any
other university or other institute of learning. If any act of plagiarism found, we are fully
responsible for every disciplinary action taken against us depending upon the seriousness of
the proven offence, even the cancellation of our degree.

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Abstract

We are doing our final year project on Biomass Gasification. The target is to utilize energy from
bio mass as wood chips in our case to produce energy. The energy will be in the form of a
combustible gas called syn gas which can be utilized as a heat source for cooking or for electric
power production which is a basic need of this time. We have designed and fabricated stratified
downdraft gasifier which would produce syn gas from wood. This combustible gas is being used as
a fuel to run a 15 kva engine generator set. Syn gas will pass through different processes which will
clean and cool the gas. The main components of the wood gas plant are:

The Gasifier
Cyclone filter
Gas cooler
Moisture seperator
3 stage filteration

The gasifier is a unit which provides conditions for non-stoichiometric combustion of wood. The
wood is burned in controlled conditions to produce wood gas.There are four zones in a gasifier
Drying, Pyrolysis, Oxidation and Reduction zone.
The gas will then go to a cyclone filter in which removal of solid particulates from the syn gas will
occur. This works on the principle of centrifugal swirl.
The gas will pass through a fabric filter which will further clean it.
In water scrubber water is sprayed with high pressure on oncoming syn gas this will clean the gas
from tar and cool it as well. The centrifugal effect here will remove excess of water which would
travel with the gas.
Blower will suck the gas from the system but it will be bypassed when the engine generator set will
start as it will draw gas from the system in place of the blower.
The conditioned gas will then be mixed with air and then be fed to the engine-generator set for
power production. If we wish to use the gas for heating purpose then we can draw it just after the
cyclone filter.

Acknowledgement
By the Grace of ALLAH ALMIGHTY what we dreamt once has now become a reality. The success
of any project depends upon the encouragement and guidelines of many others. We take this

opportunity to express our gratitude to the people who have been instrumental in the successful
completion of this project. We would like to show our greatest appreciation to our project DS Sir
Dr. Aamer Baqai. We are highly grateful to him for his tremendous support and help. We feel
motivated and encouraged every time we attend his meeting. Without his encouragement and
guidance this project would not have materialized. We are thankful to Sir Saifullah Khalid for his
technical support and guidance during the design phase. We are also thankful to Dr. Asif Ali Mirani
from NARC for his kind supervision during testing phase, the guidance and support received from
all the members who contributed and who are contributing to this project, was vital for the success
of the project. We are grateful for their constant support and help.

Contents
Table of Contents
1. History and development
2. Principal of gasification
3. Gasifier and their types

Page no
6
8
17

4.
5.
6.
7.
8.

Biomass fuel
Design and Fabrication
Analysis
Field-testing and results
References

23
28
37
64
69

Chapter 1
History and Background
Earlier Development:
In 1798 Gasification process was discovered in France and England independently and till 1850 this
technology was developed to such point that it was possible to light much of United Kingdom with
this Producer gas.During World War I small gassifiers were developed to operate vehicles, trains,

boats
b
and generators.
g
During
D
the year
y
1939 inn Europe appproximatelyy one millio
on gassifiersswere
developed
d
to operate veehicles.During the Worrld War IIera there was great deal of interest iin all
different
d
forrm of alternaative fuel duee to shortagee of conventtional fuel.By 1943 in Sw
weden more than
90% of vehhicles were being poweered by Syn gas and at the end off War there were more than
700,000
7
vecchicles that were
w operated on Produccer gas.
After
A
OPEC
C oil embargo of 1973 thhe united staatestoped woorking and fuunding Biom
mass projectss. All
the
t struggles that wascaarried out to do researchh and develeepoment on wood gas was
w on individual
bases
b
, somee under deveeloped counntries continuued to workk in it with a vision to soolve their ennergy
problems.Pr
p
roducer gas from charccoal was deeveloped in Philippine and more than 1000 units
startedoperaating, In Braazil 30 largee units were developed in
i which producer gas is generated for
industrial
i
heeat.
We
W dont knnow our futture conditio
on, our priorrities changee drasticallyy in case of emergency.A
As it
had
h been tak
ken place duuring world war era in w
which transpportation is very
v
high priiority in U.S
S and
due
d to whicch wood gassifier vehiccles were deeveloped,duuring that tennure the U.S departmennt of
defence
d
dissseminated in
nformation on
n small gasssifier in case of national emergency.

of under dev
Now
N lets haave brief lookk upon the contribution
c
veloped couuntries in the field of biomass
gassification
g
n.Uptill now
w our neighbbours have crossed
c
the milestone
m
in this field.Inndian Instituute of
Technology
T
, Delhi,Indiaan Institute of
o Technoloogy, Bombay
y, Indian Insstitute of Science, Bangalore
and
a
Indiaan Institute of Sciencce, Bangaloore these all
a dedicated their woork to Biomass
gassification
g
n.In 1990s fiirst small scaale gassifier was develop
ped but afterr that drasticcally the proggress
graph
g
reacheed at apex lim
mit.
Now
N
india is
i exporting gassifier po
ower plants upto
u
250kw.Hundreds oof gassifier are
a fabricatinng (3
to
t 250kw),in
ndustries haave been dev
veloped,reseearch on cleaning of gaas is almost complete annd in
central
c
Asia india emergge as one of the leading country in export
e
of Bioomass gassiffier
An
A outstand
ding project in Sri Lankka(small scaale gasifier)) Funded byy a Germann emer-gencyy aid
organization
o
n.It took one year in ordeer to control soot and taar contents ,ddue to the weet gas and In the
beginning
b
clleaning system had a number
n
of prroblems but it was comppensated by skilled engiineer.
By
B 2009 this small scalee gasifier haad been workking well . This
T project was launched in the conntext
of
o the Tsunaami relief.
Current positions:
Now
N
later in
n 2012 moree than 300M
MW plants weere developeed and In Appril 2013 at Finland 1322MW
biomass
b
gassification plaant was deveeloped.It is thhe biggest biiomass plantt ever made. The gasification
process
p
is not
n only lim
mited to undeer develop ccountries, In
n all over the Europe gaassifier are being
b
fabricatedannd giving beenefit not onnly to indivvidual but allso to their national griid. In India it is
estimated
e
thhat small scalle gassifier giving
g
relieff to their natiional grid off more than 1000MW
1
.
The
T countryy like Pakistaan, which is facing drasttic shortfall of electricityy is now tryiing to make their
first Biomasss gassifier. DrManzoorr Ahmad Prrof at Univeersity of Aggriculture Faaisalabad trieed to
make
m
Imberrt downdraft gassifier .W
We visited thhe university and saw thee gassifier.T
The Initiationn was

good
g
but it was unable to produce electricity.T
Two millionb
budget was allocated
a
forr the projectt, the
pictures
p
of thhat gassifierr are shown below:
b

Dr.Asifalim
D
iryani at Naational Agricculture Reseearch centerr also made updraft gassifier and thhis is
used
u
as a source to dry the
t fruits. we
w also met hhim and disccussed the pprocess.Somee research iss also
being
b
carried out in UE
ET Lahore .L
Last year college of EM
ME( Bilal Waaseem of DE
E-30 studentt and
their
t
projectt DS Sir Ahm
med Sohail made updraaft gassifier. which wass unable to produce
p
prodducer
gas
g but it waas the first innitiation in college
c
of EM
ME).
During
D
all th
his time we were also caarrying out oour own Ressearch and development we started off
o in
the
t summer of 2011 wh
hen we fabrricated woodd gas stoves and an Imbbert type dow
wn draft gassifier.
But
B the Imbert Type gassifier producced more tar content thann the limit reequired.
d
sttratified gasifier or calleed open top ggasifier by some enthusiiasts.
So we Starteed work on downdraft

Chapterr 2
Priincipal of Gassification
Biomass
B
is a natural sub
bstance , in which in the presence of
o sunlight solar energy
y is stored byy the
process
p
of photosynthesis. It mainlyy contains:
Cellulose
C
(it is an insolubble material that main co
onstitute of plant
p
cell,strong and
crystalline
c
sttructure,resisstant to hydrrolysis)
hemicellulos
h
e (it is an insoluble mateerial,having amorphous structure with little
n even with dilute acid oor base)
strength,not
s
r
resistant
to hydrolysatio
h

Lignin(complex chemical compound,integral part of secondary cell wall of plant and

most abundant organic polymer on Earth)

complete flow sheet of biomass conversion into different fuel

cellulose:

Hemicellulose:

Lignin:

complete flow sheet of biomass conversion into different fuel

Thermal conversion process for biomass involve following reaction

Pyrolysis:
biomass+ heat charcoal+oil gas
Gassification:
biomass+limited amountofoxygen producer gas
Combustion: biomass + excess ofoxygen hotcombustion product
The first step in gasification process is pyrolysis in which in the absence of air biomass is subjected
to a temperature of 350 C and the end product char coal,gases(co,co2,H2,CH4,H2o) and tar vapors
are produced.In order to better understanding ofpyrolysis, gasification and combustion we have a
example of match stick burning.

10

A more quantity picture can also be obtained by technique Thermogravimetricanalysis(TGA).

s
Thermogravimetricanalysis(TGA) shows the complete analysis of a sample of biomass when
subjected to heated in the absence of air.The TGA is a simple technique in which biomass is
suspended in balance pan in furnace and temperature is increased at known rate.
Theoretically(stoichiometric combustion) the ratio of air-to-fuelrequired for thecomplete
combustionofthebiomass, is 6:1 to 6.5. As gasification is the process in which the combustion is
carried at sub-stoichiometric conditions and the air-to-fuel ratio is 1.5:1 to 1.8:1.4
The gas that is obtained by supply this limited amount of air is known as producer gas or syn gas,
which is combustible and the device which made this process possible is called gassifier .

11

This producer gas contain 70% to 90% energy content and some thermal properties of typical
biomass and producer gas are shown in table:

Typical properties of producer gas:

Relative position of carbon,hydrogen and oxygen in solid,liquid and gaseous phase chemical
changes that have been taken place during biomass conversion is shown by phase diagrams

Thermodynamics of Gassification:
The adiabatic temperature of biomass is the temperature that would reached if any biomass come
to equilbrium with specific amount of oxygen/air(As it is impossible to achieve equilbrum but
some close state can be achieve in downdraft gassifier).The oxygen used in process is used to
determine the temperature of reaction and product.The oxygen is plotted as equivalence ratio(the
used oxygen relative that required for complete oxidation).Very low value of oxygen needed for

12

pyrolysis

Equivalence ratio of 0.25 is aproximated for gassificationand Combustion has been taken place for
greater than 1.Adiabatic reaction temperature of biomass reacting with oxygen and air.
As shown in above graph that with oxygen less than 0.25 the char is not converted completely and
with value more than 0.25 the combustion takesplace so the ideal value for equivalence ratiois 0.25
but how we can achieve that value?yes it is possible for static bed,so for fixed bed gassifier
equivalence ratio of 0.25 is achievable.The composition of gas produced is shown,Equilibrium gas
composition for reaction of air

The amount of energy remaining in the char and converted from solid to gas is shown

13

The low heating value of gas and energy per volume of gas is shown
As we know gasification is the process in which solid carbon whether in the form of coal,coke, or
char, the principle chemical reactions involving carbon,carbon monoxide, carbon dioxide,
hydrogen, water (or steam), and methane.
The reaction are given below
Combustion reactions,
C + 1/2 02 = CO - IIIMJ/krnol
(1)
CO + 1/2 O2 = C02 -283 MJ/kmol (2)
H2 + 1/2 O2 = H20 242 MJ/kmol (3)
Boudouard reaction is
C + CO2 = 2C0 +172 MJ/kmol (4)
water gas reaction is
C +H20 = CO + H2+l3l MJ/kmol (5)
And methanation reaction.
C +2 H2 S CH4 -75 Mllkmol (6)
The reaction 1,2and 3 doesnot need to be considered in equilbrium of syn gas composition.
reactions 4, 5, and 6 are enough
CO shift reaction:
CO + H20 7 CO2 + H2 4l MJ/kmol (2-7)
Calculations are used for the low temperatureC0 shift reaction, which operate at temperatures of
200-250C, Sufficiently accurate results are obtained by this aproximation .
Conversion of Sulfur into H2S and the nitrogen to NH3 and HCN. The quantities of sulfurand
nitrogen in the fuel are so small that they have a negligible effect onthe main Producer gas
components of hydrogen and carbon monoxide. However it isImportant to consider and
acknowledge the fate of sulfur and nitrogen because of their effect on environmentalemissions,
catalyst poisons, and so on.
in advance (for example, H2SlCOS=9 9.5, NH3=2S%, andt-lt.'N= tU% ot tuel nitrogen,
respectively), and their interaction with carbon, hydrogen,and oxygen is then only constraint to
mass and heat balance

14

THERMODYNAMIC OF GASIFICATION
Designers and operators should have some good knowledge about thermodynamicmodeling,
although we all know that in developing models for gasification, the requirements of a operator and
designer are totally different.
The designer has been taken the responsibility of calculating a good limited number of design
cases and by utilizing
Startupand shutdown requirements and process control requirements.
,what will be the results of that feeding.how to defined gas compositions for example, the steam
make in a syngascooler.
A Expected good model can only be built when both requirements should fulfill.The user need to to
do a lot of hardwork,he will go by number of iterative process or calculation to perform his task.
Proper calculation for gassification are based on themtodynamics, massand energy balances . In all
these calculations it is important to know the element composition and the temperature of the feed
streams .
The gassification is the process in which differentreaction have been taken place some are
exothermic and some are endothermic.
Thedesired operating temperature is obtained by playing with the exothermicand endothermic
reactions.
As In gasifiers sometime both oxygen and steam are used to control the temperature, therole of
steam is not more than that of a moderator.
There is also some other methods to equilize the temperature that is to add nitrogen or carbon
dioxide to the oxygen, or to remove heat indirectly.
Following balance equation that are applied in all gassification process
l. Carbon
2. Hydrogen
3. Oxygen
4. Heat
5. Sulfur balance.
6. Nitrogen balance.
7.Ash balance
8. Argon Balance

15

An
A integratted gasificattion combin
ned cycle
This
T
is techhnology synngas is usedd as a duel fuel in pow
wer plants because
b
of resulting caarbon
dioxide
d
whiich is less from the shhift reactionn can be coompressedExxcess heatfrrom the prim
mary
combustiona
c
and Produceer gas fired is
i then used for stram prroduction whhich is more efficient.

16

Chapter 3
Gassifier types and their applications
Gasifiers are classified according to the requirement. Each type of gasifier is used for a specific
purpose. The processes of oxidation pyrolysis drying and reduction is needed.

17

During the biomassgasification procesbiomass is pyrolized cracked or heated by thermal energy

and converted into a producer gas. As mentioned earlier this syn gas is purified by different step
andthen.
used

Gasifiers
Biomass gasifiers is a unit that heates the biomassinalow-oxygen or produce a gas)The syngas that
is produced from a gasifier is used to drive highly efficient devices for example genserator ets,
turbines and fuel cells to generate power.

18

Types Of Gasifiers
There or main types of gasifiers:

Fixedbed
Fluidizedbed

Fixed bed Gassifier:

The fixed bed gasifier has usuallybed of solid fuel particlesthroughwhichgas moveup or down. It
consists of annulus tube that contains fuel and it is then oxidized by giving an air inlet port at the
point where we need to have oxidation of the fuel. In the this type of gasifier, biomass moves down
thereactor as thegasification happenss. Fixed bed gasifiers are easy to fabricate there is a problem of
tar content in the gas. Which can be cleaned.

19

Fixed bed gasifiers are generally common. There are two common type of fixed bed
gassifier,depending upon the directionofga flow through main chamber

Updraft gassifier:
In updraft gaisifier the direction of draft of air is upward during the gasification process. And the
gas is exterated from a port which is at the top. And the controlled air
inlet is from below the grate.
Flexibility of fuel is an advantage of updraft gasifier and it can also
accept cal as fuel and it can bear high content of ash and high moisture
level.
Gasification takes place at the bottom. As the syn gas passes through the
fuel bed, it picks tars and moisture content from the fuel . So there are
condensable volatiles from the gas that get out from updraft gassifier.
gas comes out at usually 300-500C temperature.

Downdraft Gasifiers
Downdraft gasifiers are desiged for specific fuels to avoid clogging of
fuel in the reaction chamber. Downdraft wood gasifiers can only operate good on wood like
biomass material and gas is drawn from bottom of the grate
and may be above in case of double vessel as in our
case.reaction takes place in the middle.
The gasfrom the downdraf gasifiers canbe cooled and cleaned
tovery high purity by passing it throughfabricfilter or
coolingunit then it can be used inIC engines or fordirectheating
applicationwhere purity ofgas is a basicrequirement.

20

Advantages of downdraft gasifier over updraft:

The updraft gasifierachieves the highestefficiecy as the hotgaspassesthrough fuelbed and leaves it
at lowtemperature. The sensible or hidden heat as given by gas is usually used to preheat and dry
fuel.One of the major disadvantagesofupdraft gassifier is that in producer gas excessive amount of
tar is present and poor loading capability. Hence it is not suitable for running vehicle or could not
be used in ic engine.

Fluidized Bed Gasifiers:

In this gasifier the biomass is brought to a bed of char or sand where gasification takes pplace.
This system is ver exopensive and delicate and does not accommodate multiple fuels.
Prodeucaes high tar and particulate . these are used for larger scales production. Has high flow
rates..

Sometimes the fuel is fed from side and sometimes from the above. During optimum gasification
the fuel is maintained at very high 1300-1800 F. When a fuel particle at this high temperature is
introduced into environment, gasification takes place.
.It is usually seen that the temperature distribution across the fluidized bed is mostly constant
andnormal ranges of temperature is between 700Cand900C.
The large thermal or heating capacity of inert or nascent bed material and in addition to the hard
mixing related with the fluid bed allow this system to deal with a much greater quantity and
mostly having fuel quality is usually a lower.

Other Gasifier:
Twin fire gas producer:
It is called twin fire gasifier due to combination of co-current and counter-gasfier. Itusually consists
of two reaction zones. Drying of fuel , low-temperature carbonisation, and cracking or breaking at

21

high
h
temperrature of gaases is usuallly occur in the upperr zone of gaasifier , butt the permaanent
gasification
g
has been taakenplaceinlo
ower zone. T
The gas tem
mperature is usually lies between 4880 to
c
540 o C.The producer gaas that has beeen produceed by Twin-fire gasifier is mostly clean.

Cross drafft gasifier:

As
A Crossdraaftgassifier have
h
some advantages over updrafft and downddraft gasifiers, but it dooesnt
mean
m
that it is if ideal tyype.
e is very high,
h
poor CO
O 2 reductionn and
It have a lott of disadvaantages such as gas tempperature at exit
velocity
v
of gas
g is high.
It
I has some different dessign as campparedto dow
wndraft and updraft
u
gasiffiers,
f
such ass wood, charrcoal
This designn constraints limit the typpe of fuel foor working so low ash fuels
and
a cokeahss been used in
i this type of
o gassifier.
Its
I start up time
t
is very good,it pickk up in (5-10 minutes) which is noot the case in
n downdraft
ft and
updraft
u
gasiffier.
It
I operate opperates welll on dry air and
a dry fuel.

Main
M
limiitation of Gasifierss:
limitations ,which are given
g
below.
Gasiification is a very compleex and sensiitive method
d of utilizing biomass . th
here are manny
claim
ms by organiizations abouut multiple fuel
f but its hard to know without testting that a
systeem is fit for multiple
m
fueel or not.
Proccess requires about 15- 25 min to starrt and requirres periodic ffeeding of thhe biomass.
To get
g the syngaas is not diffficult task , but
b it is difficcult to get it in a proper form which has
good
d chlorific vaalue. Gas com
mposition vaaries from tiime to time. Fuel sizing is another thhing
whicch gasifiers tend
t
to depen
nd upon. Noot suitable fu
uel preparatiion is one off the importaant
cause of technicaal problems that related to gasifiers.
Gasiifier is considdered a veryy device thatt can be operrated or can generate a productive
p
orr
combbustible gas from any biiomass fuel. biomass gassification tecchnology reqquires a lot of
o
hard working, toolerance and determinatioon

Updraftffixedbedgaasifiers :

22

. As this is of notmajor importance only if the gas is used for direct heat purpose in which the tar
is burned directly.
But if we have to use the gas for engines, large components will added for gas cleaning .

Downdraft fixed bed gasifiers:

There will be constraint on . fuel requirements it must beof uniform sized from 4 to 10 cm
The moisture of the biomass not more than of 25 usually.The high temperature of the exit
producer gas is effect efficiency. Of gasification process.

Fluidized bed gasifiers:

This type of gasifier is not suitable to produce syn gas that run engines because of high tar content .
Incomplete burning of carbon have effect the energy output. There is a Complex or difficult task
needed for air to be supplied

Chapter 4
Biomass potential
Biomass issuch a fuel that is developed or produced from organic materials, one of the renewable
and sustainable source of energy used to produce cheaper electricity or other different forms of
power.
The estimated biomass production in the world is seen to be 146 billion tons a year,
Some of the basic different types of biomass are:
scrap lumber
forest debris
certain crops
manure

23

Wood isone of the largest biomass energy source today which included most of the forest
residues such as:
dead trees
branches
tree stumps
yard clippings
wood chips
Industrial biomass is grown from different types of plants i.e
Mis canthus
Switch glass
hemp,
corn
poplar,
willow,
sorghum,
sugarcane
bamboo
And a lot of tree species, including from eucalyptus to oil palm (palm oil).
As Green wood have up to 50% water by weight. soits properties or characteristics vary mostly
with moisture content.
Thechemical composition oftypical biomass is more constant than that of the differentcoals
(bituminous, anthracite, lignite) product.However more than 80% of the biomassis usually volatile
but Coal is typically only 20% volatile; which is more dif-ficult to gasify than charcoal.
Biomass mostly hasvery low sulfur content and ash content compared to coaletc.However, unlike
coal, biomass comes in a different varietyof physical forms, making it necessary to accommodate
according to the\shapes of the gasifier.So the resulting gasifier design should t be veryfuel-specific.
Analysis technique:
There are are two types of analysis:
Proximate analysis
Ultimate analysis

Proximate analysis:
The proximate analysisindirectly determines the moisture (M),volatile matter [VM], ash (A). and
fixedcarbon content (C) of a fuel, using standard ASTM tests.Moisture is analyzed by the weight
loss is usually observed at110C. . The high heating rates opposewithin an actual gasifier
demanding a higher volatile contentand a lower fixed carbon content than the slow rateasused in the
ASTM measurement, but char get fromthe component is expected to be directly proportional to
char yieldfrom the ASTM testAs shown in table given below that more than 70% of most biomass
material isvolatile under the conditions of the test. The proximateanalysisusually includes moisture
content measuredon a totally wet basis.

Ultmate analysis:

24

The ultimate analysis is only gives the chemicalcomposition and the HHV of the different fuels.
The ultimate analysis generally gives the oxygen, hydrogen, carbon nitrogen, and ash content of
the dry fuel on a different weight percentage basis.
Following are the table shows different values of moisture content of biomass by approximate
analysis

25

Biomass potiental in Pakistan

In Pakistanthesedays people are thinking to device long term economic policy due to severe
economic and social problemsThe electricity and gas shortageshavebadly affected the common
man, Industry and commercial activities.The high cost of energy mix is the main reason behind the
power shortage.
Pakistan has potential inbiomass. As Pakistan is an agrarian economy with 60% rural work man
ship. As per World Bankstatistics, more than around 26, 280, 000 hectares ofland is undercultivation in a country like Pakistan.

Agricultural Residues (reference fact and figures from online news report)
Wheat straw
rice husk
rice straw
cane trash
bagasse
cotton sticks
Are some of the important and major crop residues in Pakistan. During 2010-2011, the area under
sugarcane cultivation was estimated around 1,029,000 hectares which is more than 4% of the total
cropped area. Cane trash which makes 10% of the sugar cane is totally burned in the fields. During
the year 2010-11, around more than 63,920,000 metric tons of sugarcane was grown in this country
which in turn give trash generation of around more than 5,752,800 metric tons. It is estimated, that
the bioenergy potential of cane trash is around 9,475 GWh per year.
Cotton is another major and important corp in Pakistan and main and necessary source of raw
material to the local textile industry.
As it is estimated that cotton is grown on around more than 11% of the total cropped area in the
Pakistan. The main residue from cotton crop is cotton sticks which left after cotton picking and
constitute approximately 3 times of the cotton that produced.
Mostof the cottonsticks are used for domestic fuel in rural areas so only one-fourth of the total can
be considered as important biomass energy resource. The production of cotton sticks during 20102011 was estimated 1,474,693 metric tons which is considered equivalent to power generation
potential of around more than 3,071 GWh.
The PakistanPunjabprovince has a great potential to produce energy from biomass.it is estimated
that it can produced up to 5,400MW from thebiomass.
Entrepreneur and the Punjabgovernment are hindering and searching foralternative energy
sourcestoovercome this powershortage in the province,. The provincehaslarge amount of biomass
available in the shape of rice husk, ginning waste, cotton waste, cotton stalks, wheat straw, cotton
cob and wood chips.
The Interestinpowergeneration from rice husk was generated when it was heard that a textile mill in
our neighbor country is producing 5MW electricity from rice husk.
The study revealed that in our country rice husk has the potential to produce more than 600MW to
1,000MW per annum.
The APTMAPunjab estimated that cotton wastehas thepotential to produce more than 50-75MW.
cotton stalkin the province canproduce 100-200MW of electricity. The sugarcane crop waste also
has big potential to generate electricity.

26

It
I is estimatted that our country has potential off 2,000-3,0000MW to prroduce electrricity from ssugar
cane.
c
The Punjab
P
goverrnment estim
mated thatw
wheatstraw could
c
generaate50-100MW
W, corncob 200300MW andd wood chipss 100-300MW .

Biomass
B
Woorld Potentiaal:

27

Chapter 5
Design and Fabrication

28

criteria for functioning of a good gasifier are:

high chalorific value
H2 content
accept uptill 20 % moisture in feedstock
low content of tar In the gas
burn-out of the carbon should be (>95%), which resulted a high efiiciency
The main parameters for design are:
diameter of the constriction the throat

29

diameter of the tube

height of the reduction zone.
place or height of air inlet(s).
surface area of air inlet
air inlet angle

the velocity of air is different in different processes of the gasifier the residence time iof the gas is
tghat which tells us that how much time the gas stays in a specific zone. And the esidence time
determines the .All know that real residence time is very difficult. Also the volume-,flows of gas ,
solid that is changed through the gasifier and height of a zone is controlled by numerous ,
interdependent or correlated factors. They are totally dependent of heat generated and are used in
the different stages
. The necessary factor that determining the correct circumstances of the whole the process is mostly
taken from the cross-section of the apparatus..
As it is usually considered that in the burning or oxidation zone all the gas that present should be
burned completely and which is count to be a very fast reaction.
Besides of the total residence time, as it is calculated for the total or complete volume of a zone,
the part of each zone should be such that where the most of the reaction takes place
The actual zone where burning have been taken place is mostly thin.
The last step is pyrolysis and the reduction will start very fastly near to oxidation zone. beyond
some temperature cracking will start, and importantly charcoal is usually considered to catalyze
it. So this zone should be kept as large in dimension as possible.
It is usually considered that the charcoal level ismostly formed at the 500C level.The Cracking is
assumed to occur above 950C.
It is noted that complete cracking the tar is only seen to be possible when the charcoal zone is high
enough.The height of the pyrolysis zone that is the cause of heat transport, by conduction,
convectionand radiation.
As the actual burning zone isusually small and the reduction zone is starts at the height of the
lowest, airinlet.
The length of the zone in which the reduction process actually seems to be takes place is
determined by theprogress of the endothermic reaction..
Heat losseshappened mostly and the reaction could be stops before completion and remwdy of this
is a good insulation that isneeded. Before heating air is usually unprofitable Ahuge bed isalso not
acceptable ,it is only because of toohigh presure drop that occur, but also some heat losses.
The burning zonepositioned is usually directly at the post of the air inlet.The realburning of the
gasses is taking place only on that area which is very close to the actual inlets.
The hot zone isalready extendedthrough complete penetration of the hot gasses, directed by the
power of the enteringair.
The extensionof the hot zone is one the good step, its meansthat the complete area at the airinlet
height that The burnt gasses aretaken up usually in a circulationcaused by the stream of
air.Sobythis they enter againrcirculation the part which hot one very nearthe inlets.
Diametershould,ntlarge and the wallshoulbeinclined. It is noted that
. Thenecessary measures are usually be the height of the air inlet above the the throat at a
throatinclination of 45 .
After studying above design constraints and rules and by following some of below tables we started
fabricating our project.

30

1.1. Fire tube dimensions

Inside diameter (inches)

246
7
8
9
10
11
12
13
14

Minimum length (inches)

16
16
16
18
20
22
24
26
28
30
32

Engine power (hp)

5
15
30
40
50
65
80
100
120
140
160

Typical engine displacement (cubic inches)

10
30
60
80
100
130
160
200
240
280
320

Our gasifier Design and dimension

31

32

Tabel taken from FEMA

33

Height of gassifier
Outer cylinder diameter
Inner diameter
Air inlet nozzle diameter
Air inlet height
Air inlet angle
Constriction diameter
Constriction height
Units: Inches

60
18
8
0.75
8
60
6
11

34

Gasifier Model:

Cyclone Separator:
Cyclonesfilter is very simple and inexpensive dust and droplet separators. They are mostly used
on gasifiers. The Hot gas cyclone separators are well suited to removesolid particles larger than 10
micro-meter as it is prefiltertechnique for thegas cooler and fine particle removal.
High-efficiency cyclone separators can easily be fabricatedby a sheet-metal or welding shop. Also
the small cyclones filters are required for small gasifiersand these are not availableCommercially,
so they are designed and fabricated in custom sizes

Cyclone Operating Principles:

35

A cyclonesseparator is essentially a gravitatioonal separattor thathas beenusuallyy enhanced by a

centrifugal
c
force
f
compoonent. The equation
e
beloow are used
d to design cyyclone filterr and there iss also
a spread sheeet which is based
b
on thee following eequation

36

37

Chapter 6
Analysis
We used Solid works flow simulation Analysis to find the velocities of the
syn gas at different points in the gasifier.
Boundary conditions.

38

Velocity contour plot:

39

Streamlines

Pressure Ccontour plot:

Plot:

40

(Solid works Flow-Express report)

INPUT DATA
Initial Mesh Settings
Automatic initial mesh: On
Result resolution level: 3
Advanced narrow channel refinement: Off
Refinement in solid region: Off

Geometry Resolution
Evaluation of minimum gap size: Automatic
Evaluation of minimum wall thickness: Automatic

Computational Domain
Size
X min
X max
Y min
Y max
Z min

-0.311 m
0.311 m
-0.323 m
1.138 m
-0.229 m

41
Z max

0.304 m

Physical Features
Heat conduction in solids: Off
Time dependent: Off
Gravitational effects: On
Flow type: Laminar and turbulent
High Mach number flow: Off
Humidity: Off
Default roughness: 0 micrometer

Gravitational Settings
X component
Y component
Z component

0 m/s^2
-9.81 m/s^2
0 m/s^2

Default wall conditions: Adiabatic wall

Initial Conditions
Thermodynamic parameters
Velocity parameters

Concentrations

Static Pressure: 101325.00 Pa

Temperature: 293.20 K
Velocity vector
Velocity in X direction: 0 m/s
Velocity in Y direction: 0 m/s
Velocity in Z direction: 0 m/s
Substance fraction by mass
Carbon dioxide
0.3333
Hydrogen
0.3333

Turbulence parameters

Methane
0.3333
Turbulence intensity and length
Intensity: 2.00 %
Length: 0.006 m

Material Settings
Fluids
Carbon dioxide
Hydrogen
Methane

Boundary Conditions
Outlet Volume Flow 1
Type
Faces
Coordinate system
Reference axis
Flow parameters

Outlet Volume Flow

Face<8>@Boss-Extrude14
Face Coordinate System
X
Flow vectors direction: Normal to face

42
Volume flow rate normal to face: 0.0094 m^3/s
Inlet Volume Flow 1
Type
Faces
Coordinate system
Reference axis
Flow parameters

Thermodynamic parameters
Concentrations

Inlet Volume Flow

Face<9>@Boss-Extrude15
Face Coordinate System
X
Flow vectors direction: Normal to face
Volume flow rate normal to face: 0.0037 m^3/s
Fully developed flow: No
Inlet profile: 0
Approximate pressure: 101325.00 Pa
Temperature: 293.20 K
Substance fraction by mass
Carbon dioxide
0.3333
Hydrogen
0.3333

Turbulence parameters
Boundary layer parameters
Environment Pressure 1
Type
Faces
Coordinate system
Reference axis
Thermodynamic parameters
Concentrations

Methane
0.3333
Turbulence intensity and length
Intensity: 2.00 %
Length: 0.006 m
Boundary layer type: Turbulent
Environment Pressure
Face<2>@Boss-Extrude12
Face Coordinate System
X
Environment pressure: 101325.00 Pa
Temperature: 293.20 K
Substance fraction by mass
Carbon dioxide
0.3333
Hydrogen
0.3333

Turbulence parameters
Boundary layer parameters
Environment Pressure 2
Type
Faces
Coordinate system
Reference axis
Thermodynamic parameters
Concentrations

Methane
0.3333
Turbulence intensity and length
Intensity: 2.00 %
Length: 0.006 m
Boundary layer type: Turbulent
Environment Pressure
Face<1>@Boss-Extrude11
Face Coordinate System
X
Environment pressure: 101325.00 Pa
Temperature: 293.20 K
Substance fraction by mass

43

Carbon dioxide
0.3333
Hydrogen
0.3333

Turbulence parameters
Boundary layer parameters

Methane
0.3333
Turbulence intensity and length
Intensity: 2.00 %
Length: 0.006 m
Boundary layer type: Turbulent

Calculation Control Options

Finish Conditions
Finish conditions
Maximum travels
Goals convergence

If one is satisfied
4
Analysis interval: 5e-001

Solver Refinement
Refinement: Disabled

Results Saving
Save before refinement

On

Advanced Control Options

Flow Freezing
Flow freezing strategy

Disabled

RESULTS
Calculation Mesh
Basic Mesh Dimensions
Number of cells in X
Number of cells in Y
Number of cells in Z

10
24
8

Number Of Cells
Total cells
Fluid cells
Solid cells
Partial cells
Irregular cells
Trimmed cells
Maximum refinement level: 4

54672
22464
9829
22379
0
0

44

Goals
Name

Unit

Value

Progress

Use
in
convergence

Delta

Min/Max Table
Name
Pressure [Pa]
Temperature [K]
Velocity [m/s]
Vorticity [1/s]

Minimum
101302.53
293.20
0
8.995e-004

Maximum
101312.47
293.21
11.970
1163.979

Engineering Database
Gases
Carbon dioxide
Path: Gases Pre-Defined
Specific heat ratio (Cp/Cv): 1.287
Molecular mass: 0.0440 kg/mol
Dynamic viscosity
0.00009
0.00008
Dynamicviscosity[Pa*s]

0.00007
0.00006
0.00005
0.00004
0.00003
0.00002
0.00001
0
0

500

1000

1500

2000

Temperature[K]

2500

3000

3500

Criteria

45
Specific heat (Cp)
9000

Specificheat(Cp)[J/(kg*K)]

8000
7000
6000
5000
4000
3000
2000
1000
0
0

500

1000

1500

2000

2500

3000

3500

2500

3000

3500

Temperature[K]

Thermal conductivity

Thermalconductivity[W/(m*K)]

1.2
1
0.8
0.6
0.4
0.2
0
0

500

1000

1500

2000

Temperature[K]

Hydrogen
Path: Gases Pre-Defined
Specific heat ratio (Cp/Cv): 1.404
Molecular mass: 0.0020 kg/mol

46
Dynamic viscosity
0.000045
0.00004
Dynamicviscosity[Pa*s]

0.000035
0.00003
0.000025
0.00002
0.000015
0.00001
0.000005
0
0

500

1000

1500

2000

2500

3000

3500

3000

3500

3000

3500

Temperature[K]

Specific heat (Cp)

80000

Specificheat(Cp)[J/(kg*K)]

70000
60000
50000
40000
30000
20000
10000
0
0

500

1000

1500

2000

2500

Temperature[K]

Thermal conductivity
4

Thermalconductivity[W/(m*K)]

3.5
3
2.5
2
1.5
1
0.5
0
0

500

1000

1500

2000

Temperature[K]

Methane
Path: Gases Pre-Defined

2500

47
Specific heat ratio (Cp/Cv): 1.305
Molecular mass: 0.0160 kg/mol
Dynamic viscosity
0.000035

Dynamicviscosity[Pa*s]

0.00003
0.000025
0.00002
0.000015
0.00001
0.000005
0
0

200

400

600

800

1000

1200

1400

1200

1400

Temperature[K]

Specific heat (Cp)

6000

Specificheat(Cp)[J/(kg*K)]

5000
4000
3000
2000
1000
0
0

200

400

600

800

1000

Temperature[K]

Thermal conductivity

Thermalconductivity[W/(m*K)]

0.3
0.25
0.2
0.15
0.1
0.05
0
0

200

400

600

800

1000

Temperature[K]

1200

1400

1600

48

Cyclone Filter:

49

50

51

52

53

Boundary conditions.

During calculation:

54

55

Flow trajectories and velocity trend:

56

Velocity Cut plot Contours :

57

Flow trajectories and pressure trend.

Pressure cut plot.

Particulate study

58

59

(Solid works Flow-Express report)

INPUT DATA
Initial Mesh Settings
Automatic initial mesh: On
Result resolution level: 3
Advanced narrow channel refinement: Off
Refinement in solid region: Off

Geometry Resolution
Evaluation of minimum gap size: Automatic
Evaluation of minimum wall thickness: Automatic

Computational Domain
Size
X min
X max
Y min
Y max
Z min
Z max

Physical Features
Heat conduction in solids: Off
Time dependent: Off
Gravitational effects: On

-0.076 m
0.173 m
-0.302 m
0.279 m
-0.076 m
0.076 m

60
Flow type: Laminar and turbulent
High Mach number flow: Off
Humidity: Off
Default roughness: 0 micrometer

Gravitational Settings
X component
Y component
Z component

0 m/s^2
-9.81 m/s^2
0 m/s^2

Default wall conditions: Adiabatic wall

Initial Conditions
Thermodynamic parameters
Velocity parameters

Concentrations

Static Pressure: 101325.00 Pa

Temperature: 293.20 K
Velocity vector
Velocity in X direction: 0 m/s
Velocity in Y direction: 0 m/s
Velocity in Z direction: 0 m/s
Substance fraction by mass
Carbon dioxide
0.3333
Methane
0.3333

Turbulence parameters

Hydrogen
0.3333
Turbulence intensity and length
Intensity: 2.00 %
Length: 0.002 m

Material Settings
Fluids
Carbon dioxide
Methane
Hydrogen

Boundary Conditions
Outlet Volume Flow 1
Type
Faces
Coordinate system
Reference axis
Flow parameters
Environment Pressure 1
Type
Faces
Coordinate system
Reference axis
Thermodynamic parameters

Outlet Volume Flow

Face<2>@Boss-Extrude7
Face Coordinate System
X
Flow vectors direction: Normal to face
Volume flow rate normal to face: 0.0094 m^3/s
Environment Pressure
Face<5>@Boss-Extrude6
Face Coordinate System
X
Environment pressure: 101325.00 Pa
Temperature: 293.20 K

61
Concentrations

Substance fraction by mass

Carbon dioxide
0.3333
Methane
0.3333

Turbulence parameters
Boundary layer parameters

Hydrogen
0.3333
Turbulence intensity and length
Intensity: 2.00 %
Length: 0.002 m
Boundary layer type: Turbulent

Calculation Control Options

Finish Conditions
Finish conditions
Maximum travels
Goals convergence

If one is satisfied
4
Analysis interval: 5e-001

Solver Refinement
Refinement: Disabled

Results Saving
Save before refinement

On

Advanced Control Options

Flow Freezing
Flow freezing strategy

Disabled

RESULTS
Calculation Mesh
Basic Mesh Dimensions
Number of cells in X
Number of cells in Y
Number of cells in Z

10
22
6

Number Of Cells
Total cells
Fluid cells
Solid cells
Partial cells
Irregular cells
Trimmed cells
Maximum refinement level: 2

13745
5260
3650
4835
0
0

62

Goals
Name

Unit

Value

Progress

Use
in
convergence

Delta

Min/Max Table
Name
Pressure [Pa]
Temperature [K]
Density [kg/m^3]
Velocity [m/s]
Velocity (X) [m/s]
Velocity (Y) [m/s]
Velocity (Z) [m/s]
Temperature (Fluid) [K]
Mach Number [ ]
Vorticity [1/s]
Shear Stress [Pa]
Relative Pressure [Pa]
Heat
Transfer
Coefficient
[W/m^2/K]
Surface Heat Flux [W/m^2]

Minimum
101310.58
293.20
0.21
0
-6.274
-2.601
-5.213
293.20
0
0.005
0
-14.42
0

Maximum
101322.49
293.20
0.21
7.856
5.065
7.496
4.782
293.20
9.71e-003
675.898
0.15
-2.51
0

Crop residues productions in Pakistan ( Agri. Stat.2011)

Criteria

63

Chapter 7

64

Testing and Results

Testing was done at College Of E&ME, NUST The emissions of
the generator engine running on syn gas was analysed and The
results were satisfactory and we clearly got the data validated that
Engine running on syn gas has less emissions as compared to
petrol as a fuel.

Engine exhaust results while running on syn gas.

y Combustion efficiency 85%
y Temp pre heat

47 c

y Temp stack

141 c

y Oxygen

3.1%

y Carbon mono-oxide

751 PPM

y Carbon di-oxi

9%

y Excess air

15%

y Nitrogen oxide

346 PPM

y Nitrous oxide

363 PPM

y Sulpher di-oxide

During testing:

0 PPM

65

Fabrication:

66

67

Applications:

Tractors, harvesters, irrigation systems.

Grain drying, green house heating.
Generation of mechanical and electrical power.
Diesel as well as petrol engines

Conclusions:
y Biomass gasification an attractive energy system for Agricultural
purposes.
y Fuels for gasification: charcoal,wood and biomass residues.
y Producer gas uses in I-C engines and grain drying.
y A spark ignition engine running on producer gas on average produces
0.55-0.75 kwh of energy from 1 kg of biomass.

68

y Compression ignition engines can not run completely on producer gas.

Thus to produce 1 kwh of energy they consume 1 kg of biomass and 0.07
liters of diesel. Consequently they effect 80-85% diesel saving
y In future, producer gas in fuel cell and small scale irrigation systems for
developing countries offer the greatest potentialities.

69

References
1. Solar Energy Research Institute (SERI), Generator Gas The Swedish
Experience from 1939-1945, SERI, Golden, Colorado, 1979.
2. Reed, T. B., Graboski, M., and Markson, M., The SERI High Pressure
Oxygen Gasifier, Report SERI/TP-234-1455R, Solar Energy Research
Institute, Golden, Colorado, Feb. 1982.
3. H. LaFontaine, Biomass Energy Foundation, INC. Miami, Florida.
Federal Emergency Management Agency (FEMA) Construction of a
Simplified Wood Gas for Fueling Internal Combustion Engines in a
Petrolium Emergency 1989.
4. Wood gas as engine fuel, Food and Agriculture Organization of the
United Nations (FAO) 1986.