Analise técnica, econômica e ecológica da incorporação de sistemas de gaseificação de bagaço de cana-de-açúcar no setor sucroalcooleiro: uso de ciclos combinados para o aumento da oferta de eletricidade

Pós-graduação em Engenharia Mecânica - FEG

Biomass Gasification - Process analysis and dimensioning aspects for downdraft units and gas cleaning lines

In such territories where food production is mostly scattered in several small / medium size or even domestic farms, a lot of heterogeneous residues are produced yearly, since farmers usually carry out different activities in their properties. The amount and composition of farm residues, therefore, widely change during year, according to the single production process periodically achieved. Coupling high efficiency micro-cogeneration energy units with easy handling biomass conversion equipments, suitable to treat different materials, would provide many important advantages to the farmers and to the community as well, so that the increase in feedstock flexibility of gasification units is nowadays seen as a further paramount step towards their wide spreading in rural areas and as a real necessity for their utilization at small scale. Two main research topics were thought to be of main concern at this purpose, and they were therefore discussed in this work: the investigation of fuels properties impact on gasification process development and the technical feasibility of small scale gasification units integration with cogeneration systems. According to these two main aspects, the present work was thus divided in two main parts. The first one is focused on the biomass gasification process, that was investigated in its theoretical aspects and then analytically modelled in order to simulate thermo-chemical conversion of different biomass fuels, such as wood (park waste wood and softwood), wheat straw, sewage sludge and refuse derived fuels. The main idea is to correlate the results of reactor design procedures with the physical properties of biomasses and the corresponding working conditions of gasifiers (temperature profile, above all), in order to point out the main differences which prevent the use of the same conversion unit for different materials. At this scope, a gasification kinetic free model was initially developed in Excel sheets, considering different values of air to biomass ratio and the downdraft gasification technology as particular examined application. The differences in syngas production and working conditions (process temperatures, above all) among the considered fuels were tried to be connected to some biomass properties, such elementary composition, ash and water contents. The novelty of this analytical approach was the use of kinetic constants ratio in order to determine oxygen distribution among the different oxidation reactions (regarding volatile matter only) while equilibrium of water gas shift reaction was considered in gasification zone, by which the energy and mass balances involved in the process algorithm were linked together, as well. Moreover, the main advantage of this analytical tool is the easiness by which the input data corresponding to the particular biomass materials can be inserted into the model, so that a rapid evaluation on their own thermo-chemical conversion properties is possible to be obtained, mainly based on their chemical composition A good conformity of the model results with the other literature and experimental data was detected for almost all the considered materials (except for refuse derived fuels, because of their unfitting chemical composition with the model assumptions). Successively, a dimensioning procedure for open core downdraft gasifiers was set up, by the analysis on the fundamental thermo-physical and thermo-chemical mechanisms which are supposed to regulate the main solid conversion steps involved in the gasification process. Gasification units were schematically subdivided in four reaction zones, respectively corresponding to biomass heating, solids drying, pyrolysis and char gasification processes, and the time required for the full development of each of these steps was correlated to the kinetics rates (for pyrolysis and char gasification processes only) and to the heat and mass transfer phenomena from gas to solid phase. On the basis of this analysis and according to the kinetic free model results and biomass physical properties (particles size, above all) it was achieved that for all the considered materials char gasification step is kinetically limited and therefore temperature is the main working parameter controlling this step. Solids drying is mainly regulated by heat transfer from bulk gas to the inner layers of particles and the corresponding time especially depends on particle size. Biomass heating is almost totally achieved by the radiative heat transfer from the hot walls of reactor to the bed of material. For pyrolysis, instead, working temperature, particles size and the same nature of biomass (through its own pyrolysis heat) have all comparable weights on the process development, so that the corresponding time can be differently depending on one of these factors according to the particular fuel is gasified and the particular conditions are established inside the gasifier. The same analysis also led to the estimation of reaction zone volumes for each biomass fuel, so as a comparison among the dimensions of the differently fed gasification units was finally accomplished. Each biomass material showed a different volumes distribution, so that any dimensioned gasification unit does not seem to be suitable for more than one biomass species. Nevertheless, since reactors diameters were found out quite similar for all the examined materials, it could be envisaged to design a single units for all of them by adopting the largest diameter and by combining together the maximum heights of each reaction zone, as they were calculated for the different biomasses. A total height of gasifier as around 2400mm would be obtained in this case. Besides, by arranging air injecting nozzles at different levels along the reactor, gasification zone could be properly set up according to the particular material is in turn gasified. Finally, since gasification and pyrolysis times were found to considerably change according to even short temperature variations, it could be also envisaged to regulate air feeding rate for each gasified material (which process temperatures depend on), so as the available reactor volumes would be suitable for the complete development of solid conversion in each case, without even changing fluid dynamics behaviour of the unit as well as air/biomass ratio in noticeable measure. The second part of this work dealt with the gas cleaning systems to be adopted downstream the gasifiers in order to run high efficiency CHP units (i.e. internal engines and micro-turbines). Especially in the case multi–fuel gasifiers are assumed to be used, weightier gas cleaning lines need to be envisaged in order to reach the standard gas quality degree required to fuel cogeneration units. Indeed, as the more heterogeneous feed to the gasification unit, several contaminant species can simultaneously be present in the exit gas stream and, as a consequence, suitable gas cleaning systems have to be designed. In this work, an overall study on gas cleaning lines assessment is carried out. Differently from the other research efforts carried out in the same field, the main scope is to define general arrangements for gas cleaning lines suitable to remove several contaminants from the gas stream, independently on the feedstock material and the energy plant size The gas contaminant species taken into account in this analysis were: particulate, tars, sulphur (in H2S form), alkali metals, nitrogen (in NH3 form) and acid gases (in HCl form). For each of these species, alternative cleaning devices were designed according to three different plant sizes, respectively corresponding with 8Nm3/h, 125Nm3/h and 350Nm3/h gas flows. Their performances were examined on the basis of their optimal working conditions (efficiency, temperature and pressure drops, above all) and their own consumption of energy and materials. Successively, the designed units were combined together in different overall gas cleaning line arrangements, paths, by following some technical constraints which were mainly determined from the same performance analysis on the cleaning units and from the presumable synergic effects by contaminants on the right working of some of them (filters clogging, catalysts deactivation, etc.). One of the main issues to be stated in paths design accomplishment was the tars removal from the gas stream, preventing filters plugging and/or line pipes clogging At this scope, a catalytic tars cracking unit was envisaged as the only solution to be adopted, and, therefore, a catalytic material which is able to work at relatively low temperatures was chosen. Nevertheless, a rapid drop in tars cracking efficiency was also estimated for this same material, so that an high frequency of catalysts regeneration and a consequent relevant air consumption for this operation were calculated in all of the cases. Other difficulties had to be overcome in the abatement of alkali metals, which condense at temperatures lower than tars, but they also need to be removed in the first sections of gas cleaning line in order to avoid corrosion of materials. In this case a dry scrubber technology was envisaged, by using the same fine particles filter units and by choosing for them corrosion resistant materials, like ceramic ones. Besides these two solutions which seem to be unavoidable in gas cleaning line design, high temperature gas cleaning lines were not possible to be achieved for the two larger plant sizes, as well. Indeed, as the use of temperature control devices was precluded in the adopted design procedure, ammonia partial oxidation units (as the only considered methods for the abatement of ammonia at high temperature) were not suitable for the large scale units, because of the high increase of reactors temperature by the exothermic reactions involved in the process. In spite of these limitations, yet, overall arrangements for each considered plant size were finally designed, so that the possibility to clean the gas up to the required standard degree was technically demonstrated, even in the case several contaminants are simultaneously present in the gas stream. Moreover, all the possible paths defined for the different plant sizes were compared each others on the basis of some defined operational parameters, among which total pressure drops, total energy losses, number of units and secondary materials consumption. On the basis of this analysis, dry gas cleaning methods proved preferable to the ones including water scrubber technology in al of the cases, especially because of the high water consumption provided by water scrubber units in ammonia adsorption process. This result is yet connected to the possibility to use activated carbon units for ammonia removal and Nahcolite adsorber for chloride acid. The very high efficiency of this latter material is also remarkable. Finally, as an estimation of the overall energy loss pertaining the gas cleaning process, the total enthalpy losses estimated for the three plant sizes were compared with the respective gas streams energy contents, these latter obtained on the basis of low heating value of gas only. This overall study on gas cleaning systems is thus proposed as an analytical tool by which different gas cleaning line configurations can be evaluated, according to the particular practical application they are adopted for and the size of cogeneration unit they are connected to.

Numerical simulations of microphysical processes in pyro-convective clouds

Hochreichende Konvektion über Waldbränden ist eine der intensivsten Formen von atmosphärischer Konvektion. Die extreme Wolkendynamik mit hohen vertikalen Windgeschwindigkeiten (bis 20 m/s) bereits an der Wolkenbasis, hohen Wasserdampfübersättigungen (bis 1%) und die durch das Feuer hohen Anzahlkonzentration von Aerosolpartikeln (bis 100000 cm^-3) bilden einen besonderen Rahmen für Aerosol-Wolken Wechselwirkungen.Ein entscheidender Schritt in der mikrophysikalischen Entwicklung einer konvektiven Wolke ist die Aktivierung von Aerosolpartikeln zu Wolkentropfen. Dieser Aktivierungsprozess bestimmt die anfängliche Anzahl und Größe der Wolkentropfen und kann daher die Entwicklung einer konvektiven Wolke und deren Niederschlagsbildung beeinflussen. Die wichtigsten Faktoren, welche die anfängliche Anzahl und Größe der Wolkentropfen bestimmen, sind die Größe und Hygroskopizität der an der Wolkenbasis verfügbaren Aerosolpartikel sowie die vertikale Windgeschwindigkeit. Um den Einfluss dieser Faktoren unter pyro-konvektiven Bedingungen zu untersuchen, wurden numerische Simulationen mit Hilfe eines Wolkenpaketmodells mit detaillierter spektraler Beschreibung der Wolkenmikrophysik durchgeführt. Diese Ergebnisse können in drei unterschiedliche Bereiche abhängig vom Verhältnis zwischen vertikaler Windgeschwindigkeit und Aerosolanzahlkonzentration (w/NCN) eingeteilt werden: (1) ein durch die Aerosolkonzentration limitierter Bereich (hohes w/NCN), (2) ein durch die vertikale Windgeschwindigkeit limitierter Bereich (niedriges w/NCN) und (3) ein Übergangsbereich (mittleres w/NCN). Die Ergebnisse zeigen, dass die Variabilität der anfänglichen Anzahlkonzentration der Wolkentropfen in (pyro-) konvektiven Wolken hauptsächlich durch die Variabilität der vertikalen Windgeschwindigkeit und der Aerosolkonzentration bestimmt wird. rnUm die mikrophysikalischen Prozesse innerhalb der rauchigen Aufwindregion einer pyrokonvektiven Wolke mit einer detaillierten spektralen Mikrophysik zu untersuchen, wurde das Paketmodel entlang einer Trajektorie innerhalb der Aufwindregion initialisiert. Diese Trajektore wurde durch dreidimensionale Simulationen eines pyro-konvektiven Ereignisses durch das Model ATHAM berechnet. Es zeigt sich, dass die Anzahlkonzentration der Wolkentropfen mit steigender Aerosolkonzentration ansteigt. Auf der anderen Seite verringert sich die Größe der Wolkentropfen mit steigender Aerosolkonzentration. Die Reduzierung der Verbreiterung des Tropfenspektrums stimmt mit den Ergebnissen aus Messungen überein und unterstützt das Konzept der Unterdrückung von Niederschlag in stark verschmutzen Wolken.Mit Hilfe des Models ATHAM wurden die dynamischen und mikrophysikalischen Prozesse von pyro-konvektiven Wolken, aufbauend auf einer realistischen Parametrisierung der Aktivierung von Aerosolpartikeln durch die Ergebnisse der Aktivierungsstudie, mit zwei- und dreidimensionalen Simulationen untersucht. Ein modernes zweimomenten mikrophysikalisches Schema wurde in ATHAM implementiert, um den Einfluss der Anzahlkonzentration von Aerosolpartikeln auf die Entwicklung von idealisierten pyro-konvektiven Wolken in US Standardamtosphären für die mittleren Breiten und den Tropen zu untersuchen. Die Ergebnisse zeigen, dass die Anzahlkonzentration der Aerosolpartikel die Bildung von Regen beeinflusst. Für geringe Aerosolkonzentrationen findet die rasche Regenbildung hauptsächlich durch warme mikrophysikalische Prozesse statt. Für höhere Aerosolkonzentrationen ist die Eisphase wichtiger für die Bildung von Regen. Dies führt zu einem verspäteten Einsetzen von Niederschlag für verunreinigtere Atmosphären. Außerdem wird gezeigt, dass die Zusammensetzung der Eisnukleationspartikel (IN) einen starken Einfluss auf die dynamische und mikrophysikalische Struktur solcher Wolken hat. Bei sehr effizienten IN bildet sich Regen früher. Die Untersuchung zum Einfluss des atmosphärischen Hintergrundprofils zeigt eine geringe Auswirkung der Meteorologie auf die Sensitivität der pyro-konvektiven Wolken auf diernAerosolkonzentration. Zum Abschluss wird gezeigt, dass die durch das Feuer emittierte Hitze einen deutlichen Einfluss auf die Entwicklung und die Wolkenobergrenze von pyro-konvektive Wolken hat. Zusammenfassend kann gesagt werden, dass in dieser Dissertation die Mikrophysik von pyrokonvektiven Wolken mit Hilfe von idealisierten Simulation eines Wolkenpaketmodell mit detaillierte spektraler Mikrophysik und eines 3D Modells mit einem zweimomenten Schema im Detail untersucht wurde. Es wird gezeigt, dass die extremen Bedingungen im Bezug auf die vertikale Windgeschwindigkeiten und Aerosolkonzentrationen einen deutlichen Einfluss auf die Entwicklung von pyro-konvektiven Wolken haben.

Photochemie der Troposphäre in niedrigen und mittleren Breiten: Die Rolle von Konvektion

Ozon (O3) ist in der Atmosphäre ein wichtiges Oxidanz und Treibhausgas. Während die höchsten Konzentrationen in der Stratosphäre beobachtet werden und die vor der gefährlichen UV-Strahlung schützende Ozonschicht bilden, können sich signifikante Änderungen der Ozon-Konzentration in der Region der Tropopause auf das Klima der Erde auswirken. Des Weiteren ist Ozon eine der Hauptquellen für das Hydroxylradikal (OH) und nimmt damit entscheidend Einfluss auf die Oxidationskraft der Atmosphäre. Der konvektive Transport von Ozon und seinen Vorläufergasen aus Regionen nahe der Erdoberfläche in die freie Troposphäre beeinflusst das Budget dieser Spezies in der Tropopausenregion.rnDie Datengrundlage der Studie in der vorliegenden Arbeit basiert auf den flugzeuggetragenen Messkampagnen GABRIEL 2005 (Suriname, Südamerika) sowie HOOVER I 2006 und HOOVER II 2007 (beide in Europa). Mit dem zur Verfügung stehenden Datensatz wird das Ozonbudget in der freien, unbelasteten Hintergrundatmosphäre und in der durch hochreichende Konvektion gestörten, oberen Troposphäre untersucht. Anhand der auf in-situ Messungen von O3, NO, OH, HO2 und dem aktinischen Strahlungsfluss basierten Berechnung der Netto-Ozonproduktionsrate (NOPR) werden für das Messgebiet Ozontendenzen in der unbelasteten Troposphäre abgeleitet und mit Simulationen des globalen Chemie-Transport-Modells MATCH-MPIC verglichen. Mit Hilfe zweier Fallstudien in den Tropen in Südamerika und den mittleren Breiten in Europa werden die Auswirkungen von hochreichender Konvektion auf die obere Troposphäre quantifiziert.rnDie Ergebnisse zeigen für die Grenzschicht in niedrigen und mittleren Breiten eine eindeutige Tendenz zur Produktion von Ozon, was für den tropischen Regenwald in der Messregion nicht der allgemeinen Erwartung entsprach, nach der diese Region durch die Zerstörung von Ozon charakterisiert sein sollte. In der oberen Troposphäre ab etwa 7 km wird für die beiden Regionen eine leichte Tendenz zur Ozonproduktion beobachtet. Signifikante Unterschiede zeigen die Ergebnisse für die mittlere Troposphäre. Während die Tropen in dieser Region durch eine eindeutige Tendenz zur Zerstörung von Ozon charakterisiert sind, lässt sich über den mittleren Breiten zwar eine hohe photochemische Aktivität aber keine derart klare Tendenz feststellen. Die hohen Breiten zeichnen sich durch eine neutrale Troposphäre in Bezug auf die Ozontendenz aus und weisen kaum photochemische Aktivität auf. Der Vergleich dieser Ergebnisse mit dem MATCH-MPIC Modell zeigt in weiten Teilen der Messregionen eine grundlegende Übereinstimmung in der Tendenz zur Produktion oder Zerstörung von Ozon. Die absoluten Werte werden vom Modell aber generell unterschätzt. Signifikante Unterschiede zwischen in-situ Daten und Modellsimulationen werden in der Grenzschicht über dem tropischen Regenwald identifiziert.rnDer Einfluss der Konvektion ist durch eine signifikant erhöhte NOPR gekennzeichnet. In dieser Arbeit wird in den Tropen mit einem Median-Wert von 0.20 ppbv h−1 eine um den Faktor 3.6 erhöhte NOPR im Vergleich zur ungestörten oberen Troposphäre abgeschätzt. In den mittleren Breiten führt die um eine Größenordnung höhere NO-Konzentration zu einem Wert von 1.89 ppbv h−1, was einer Überhöhung um einen Faktor 6.5 im Vergleich zum ungestörten Zustand entspricht. Diese Ergebnisse zeigen für beide Regionen in der oberen Troposphäre eine erhöhte Ozonproduktion als Folge konvektiver Aktivität. rnrnHochreichende Konvektion ist zudem ein sehr effektiver Mechanismus für den Vertikaltransport aus der Grenzschicht in die obere Troposphäre. Die schnelle Hebung in konvektiven Wolken führt bei Spurengasen mit Quellen an der Erdoberfläche zu einer Erhöhung ihrer Konzentration in der oberen Troposphäre. Die hochgradig löslichen Spurenstoffe Formaldehyd (HCHO) und Wasserstoffperoxid (H2O2) sind wichtige Vorläufergase der HOx-Radikale. Es wird angenommen, dass sie aufgrund ihrer Löslichkeit in Gewitterwolken effektiv ausgewaschen werden.rnIn der vorliegenden Arbeit wird eine Fallstudie von hochreichender Konvektion im Rahmen des HOOVER II Projekts im Sommer 2007 analysiert. Am 19.07.2007 entwickelten sich am Nachmittag am Südostrand eines in nordöstlicher Richtung ziehenden mesoskaligen konvektiven Systems drei zunächst isolierte konvektive Zellen. Flugzeuggetragene Messungen in der Aus- und der Einströmregion einer dieser Gewitterzellen stellen einen exzellenten Datensatz bereit, um die Auswirkungen von hochreichender Konvektion auf die Verteilung verschiedener Spurengase in der oberen Troposphäre zu untersuchen. Der Vergleich der Konzentrationen von Kohlenstoffmonoxid (CO) und Methan (CH4) zwischen der oberen Troposphäre und der Grenzschicht deutet auf einen nahezu unverdünnten Transport dieser langlebigen Spezies in der konvektiven Zelle hin. Die Verhältnisse betragen (0.94±0.04) für CO und (0.99±0.01) für CH4. Für die löslichen Spezies HCHO und H2O2 beträgt dieses Verhältnis in der Ausströmregion (0.55±0.09) bzw. (0.61±0.08). Dies ist ein Indiz dafür, dass diese Spezies nicht so effektiv ausgewaschen werden wie angenommen. Zum besseren Verständnis des Einflusses der Konvektion auf die Budgets dieser Spezies in der oberen Troposphäre wurden im Rahmen dieser Arbeit Boxmodell-Studien für den Beitrag der photochemischen Produktion in der Ausströmregion durchgeführt, wobei die gemessenen Spezies und Photolysefrequenzen als Randbedingungen dienten. Aus den Budgetbetrachtungen für HCHO und H2O2 wird eine Auswascheffizienz von (67±24) % für HCHO und (41±18) % für H2O2 abgeschätzt. Das für H2O2 überraschende Ergebnis lässt darauf schließen, dass dieses Molekül in einer Gewitterwolke deutlich effektiver transportiert werden kann, als aufgrund seiner hohen Löslichkeit aus der Henry-Konstanten zu erwarten wäre. Das Ausgasen von gelöstem H2O2 beim Gefrieren eines Wolkentropfens, d.h. ein Retentionskoeffizient kleiner 1, ist ein möglicher Mechanismus, der zum beobachteten Mischungsverhältnis dieser löslichen Spezies in der Ausströmregion beitragen kann.

Air-steam gasification of sewage sludge in a bubbling bed reactor: Effect of alumina as a primary catalyst

Numerous references can be found in scientific literature regarding biomass gasification. However, there are few works related to sludge gasification. A study of sewage sludge gasification process in a bubbling fluidised bed gasifier on a laboratory scale is here reported. The aim was to find the optimum conditions for reducing the production of tars and gain more information on the influx of different operating variables in the products resulting from the gasification of this waste. The variables studied were the equivalence ratio (ER), the steam-biomass ratio (SB) and temperature. Specifically, the ER was varied from 0.2 to 0.4, the SB from 0 to 1 and the temperature from 750 °C (1023 K) to 850 °C (1123 K). Although it was observed that tar production could be considerably reduced (up to 72%) by optimising the gasification conditions, the effect of using alumina (aluminium oxide, of proven efficacy in destroying the tar produced in biomass gasification) as primary catalyst in air and air-steam mixture tests was also verified. The results show that by adding small quantities of alumina to the bed (10% by weight of fed sludge) considerable reductions in tar production can be obtained (up to 42%) improving, at the same time, the lower heating value (LHV) of the gas and carbon conversion.

Sewage sludge gasification. Dolomite performance under different operating conditions

Gasification is a technology that can replace traditional management alternatives used up to date to deal with this waste (landfilling, composting and incineration) and which fulfils the social, environmental and legislative requirements. The main products of sewage sludge gasification are permanent gases (useful to generate energy or to be used as raw material in chemical synthesis processes), liquids (tars) and char. One of the main problems to be solved in gasification is tar production. Tars are organic impurities which can condense at relatively high temperatures making impossible to use the produced gases for most applications. This work deals with the effect of some primary tar removal processes (performed inside the gasifier) on sewage sludge gasification products. For this purpose, analysis of the gas composition, tar production, cold gas efficiency and carbon conversion were carried out. The tests were performed with air in a laboratory scale plant consisting mainly of a bubbling bed gasifier. No catalyzed and catalyzed (10% wt of dolomite in the bed and in the feeding) tests were carried out at different temperatures (750ºC, 800ºC and 850ºC) in order to know the effect of these parameters in the gasification products. As far as tars were concerned, qualitative and quantitative tar composition was determined. In all tests the Equivalence Ratio (ER) was kept at 0.3. Temperature is one of the most influential variables in sewage sludge gasification. Higher temperatures favoured hydrogen and CO production while CO2 content decreased, which might be partially explained by the effect of the cracking, Boudouard and CO2 reforming reactions. At 850ºC, cold gas efficiency and carbon conversion reached 49% and 76%, respectively. The presence of dolomite as catalyst increased the production of H2 reaching contents of 15.5% by volume at 850 °C. Similar behaviour was found for CO whereas CO2 and CnHm (light hydrocarbons) production decreased. In the presence of dolomite, a tar reduction of up to 51% was reached in comparison with no catalyzed tests, as well as improvements on cold gas efficiency and carbon conversion. Several assays were developed in order to test catalyst performance under more rough gasification conditions. For this purpose, the throughput value (TR), defined as kg sludge “as received” fed to the gasifier per hour and per m2 of cross sectional area of the gasifier, was modified. Specifically, the TR values used were 110 (reference value), 215 and 322 kg/h·m2. When TR increased, the H2, CO and CH4 production decreased while the CO2 and the CnHm production increased. Tar production increased drastically with TR during no catalysed tests what is related to the lower residence time of the gas inside the reactor. Nevertheless, even at TR=322 kg/h·m2, tar production decreased by nearly 50% with in-bed use of dolomite in comparison with no catalyzed assays under the same operating conditions. Regarding relative tar composition, there was an increase in benzene and naphthalene content when temperature increased while the content of the rest of compounds decreased. The dolomite seemed to be effective all over the range of molecular weight studied showing tar removal efficiencies between 35-55% in most cases. High values of the TR caused a significant increase in tar production but a slight effect on tar composition.

The Microphysical Structure of Mesoscale Convective Systems

Thesis (Ph.D.)--University of Washington, 2016-05

A quasi-chemical viscosity model for fully liquid slags in the Al2O3-CaO-'FeO'-SiO2 system

A structurally based viscosity model for fully liquid silicate slags has been proposed and applied to the Al2O3-CaO-'FeO'-SiO2 system at metallic iron saturation. The model links the slag viscosity to the internal structure of melts through the concentrations of various anion/cation structural units (SUs). The concentrations of structural units are equivalent to the second nearest neighbor bond concentrations calculated by the quasi-chemical thermodynamic model. This viscosity model describes experimental data over the entire temperature and composition range within the Al2O3-CaO-'FeO'-SiO2 system at metallic iron saturation and can be extended to other industrial slag systems.

Characterization of sugar cane waste biomass derived chars from pressurized gasification

There is interest in the use of sugar cane waste biomass for electricity cogeneration, by integrated gasification combined cycle (IGCC) processes. This paper describes one aspect of an overall investigation into the reactivity of cane wastes under pressurized IGGC conditions, for input into process design. There is currently a gap in understanding the morphological transformations experienced by cane waste biomass undergoing conversion to char during pressurized gasification, which is addressed by this work. Char residuals remaining after pressurized pyrolysis and carbon dioxide gasification were analysed by optical microscope, nitrogen (BET) adsorption analysis, SEM/EDS, TEM/EDS and XPS techniques. The amorphous cane plant silica structures were found to remain physically intact during entrained flow gasification, but chemically altered in the presence of other inorganic species. The resulting crystalline silicates were mesoporous (with surface areas of the order of 20 m(2) g(-1)) and contributed to much of the otherwise limited pore volume present in the residual chars. Coke deposition and intimate blending of the carbonaceous and inorganic species was identified. Progressive sintering of the silicates appeared to trap coke deposits in the pore network. As a result ash residuals showed significant organic contents, even after extensive additional oxidation in air. The implications of the findings are that full conversion of cane trash materials under pressurized IGCC conditions may be significantly hampered by the silica structures inherent in these biomass materials and that further research of the contributing phenomena is recommended.

Intermediate pyrolysis:a sustainable biomass-to-energy concept-biothermal valorisation of biomass (BtVB) process

Wastewater treatment coupled with energy crop cultivation provides an attractive source of cheap feedstock. This study reviews an advanced, closed-loop bioenergy conversion process [biothermal valorisation of biomass (BtVB)], in which pyroformer is coupled to a gasifier. BtVB process was developed at European Bioenergy Research Institute (EBRI), Aston University, UK and demonstrates an improved method for thermal conversion of ash-rich biomass.

Cost and performance analysis of new wood-fuelled power plant concepts

The objective of the thesis was to analyse several process configurations for the production of electricity from biomass. Process simulation models using AspenPlus aimed at calculating the industrial performance of power plant concepts were built, tested, and used for analysis. The criteria used in analysis were performance and cost. All of the advanced systems appear to have higher efficiencies than the commercial reference, the Rankine cycle. However, advanced systems typically have a higher cost of electricity (COE) than the Rankine power plant. High efficiencies do not reduce fuel costs enough to compensate for the high capital costs of advanced concepts. The successful reduction of capital costs would appear to be the key to the introduction of the new systems. Capital costs account for a considerable, often dominant, part of the cost of electricity in these concepts. All of the systems have higher specific investment costs than the conventional industrial alternative, i.e. the Rankine power plant; Combined beat and power production (CUP) is currently the only industrial area of application in which bio-power costs can be considerably reduced to make them competitive. Based on the results of this work, AsperiPlus is an appropriate simulation platform. How-ever, the usefulness of the models could be improved if a number of unit operations were modelled in greater detail. The dryer, gasifier, fast pyrolysis, gas engine and gas turbine models could be improved.

Downdraft gasification of biomass

The objectives of this research were to investigate the parameters affecting the gasification process within downdraft gasifiers using biomass feedstocks. In addition to investigations with an open-core gasifier, a novel open-topped throated gasifier was designed and used. A sampling system was designed and installed to determine the water, tar and particular content of the raw product gas. This permitted evaluation of the effects of process parameters and reactor design on tar and particular production, although a large variation was found for the particulate measurements due to the capture of large particles. For both gasifiers, the gasification process was studied in order to identify and compare the mechanisms controlling the position and shape of the reaction zones. The stability of the reaction zone was found to be governed by the superficial gas velocity within the reactor. A superficial gas velocity below 0.2 Nms-1 resulted in a rising reaction zone in both gasifiers. Turndown is achieved when the rate of char production by flaming pyrolysis equals the rate of char gasification over a range of throughputs. A turndown ratio of 2:1 was achieved for the hybrid-throated gasifier, compared to 1.3:1 for the open-core. It is hypothesized that pyrolysis is a surface area phenomenon, and that in the hybrid gasifier the pyrolysis front can expand to form a dome-shape. The rate of char gasification is believed to increase as the depth of the gasification zone increases. Vibration of the open-core reactor bed decreased the bed pressure drop, reduced the voidage, aided solids flow and gave a minor improvement in the product gas energy content. Insulation improved the performance of both reactors by reducing heat losses resulting in a reduced air to feed ratio requirement. The hybrid gasifier gave a higher energy conversion efficiency, a higher product gas heating value, and a lower tar content than the open-core gasifier due to efficient gas mixing in a high temperature tar cracking region below the throat and reduced heat losses.

The design, evaluation and costing of biomass gasifiers

The objective of this study has been to enable a greater understanding of the biomass gasification process through the development and use of process and economic models. A new theoretical equilibrium model of gasification is described using the operating condition called the adiabatic carbon boundary. This represents an ideal gasifier working at the point where the carbon in the feedstock is completely gasified. The model can be used as a `target' against which the results of real gasifiers can be compared, but it does not simulate the results of real gasifiers. A second model has been developed which uses a stagewise approach in order to model fluid bed gasification, and its results have indicated that pyrolysis and the reactions of pyrolysis products play an important part in fluid bed gasifiers. Both models have been used in sensitivity analyses: the biomass moisture content and gasifying agent composition were found to have the largest effects on performance, whilst pressure and heat loss had lesser effects. Correlations have been produced to estimate the total installed capital cost of gasification systems and have been used in an economic model of gasification. This has been used in a sensitivity analysis to determine the factors which most affect the profitability of gasification. The most important influences on gasifier profitability have been found to be feedstock cost, product selling price and throughput. Given the economic conditions of late 1985, refuse gasification for the production of producer gas was found to be viable at throughputs of about 2.5 tonnes/h dry basis and above, in the metropolitan counties of the United Kingdom. At this throughput and above, the largest element of product gas cost is the feedstock cost, the cost element which is most variable.

Gasification of biomass in a downdraft reactor

The objective of this study was to design, construct, commission and operate a laboratory scale gasifier system that could be used to investigate the parameters that influence the gasification process. The gasifier is of the open-core variety and is fabricated from 7.5 cm bore quartz glass tubing. Gas cleaning is by a centrifugal contacting scrubber, with the product gas being flared. The system employs an on-line dedicated gas analysis system, monitoring the levels of H2, CO, CO2 and CH4 in the product gas. The gas composition data, as well as the gas flowrate, temperatures throughout the system and pressure data is recorded using a BBC microcomputer based data-logging system. Ten runs have been performed using the system of which six were predominantly commissioning runs. The main emphasis in the commissioning runs was placed on the gas clean-up, the product gas cleaning and the reactor bed temperature measurement. The reaction was observed to occur in a narrow band, of about 3 to 5 particle diameters thick. Initially the fuel was pyrolysed, with the volatiles produced being combusted and providing the energy to drive the process, and then the char product was gasified by reaction with the pyrolysis gases. Normally, the gasifier is operated with reaction zone supported on a bed of char, although it has been operated for short periods without a char bed. At steady state the depth of char remains constant, but by adjusting the air inlet rate it has been shown that the depth of char can be increased or decreased. It has been shown that increasing the depth of the char bed effects some improvement in the product gas quality.

Technoeconomic modelling of coal conversion processes for liquid fuel production

Since the oil crisis of 1973 considerable interest has been shown in the production of liquid fuels from alternative sources. In particular processes utilizing coal as the feedstock have received considerable interest. These processes can be divided into direct and indirect liquefaction and pyrolysis. This thesis describes the modelling of indirect coal liquefaction processes for the purpose of performing technical and economic assessment of the production of liquid fuels from coal and lignite, using a variety of gasification and synthesis gas liquefaction technologies. The technologies were modeled on a 'step model' basis where a step is defined as a combination of individual unit operations which together perform a significant function on the process streams, such as a methanol synthesis step or a gasification and physical gas cleaning step. Sample results of the modelling, covering a wide range of gasifiers, liquid synthesis processes and products are presented in this thesis. Due to the large number of combinations of gasifier, liquid synthesis processes, products and economic sensitivity cases, a complete set of results is impractical to present in a single publication. The main results show that methanol is the cheapest fuel to produce from coal followed by fuel alcohol, diesel from the Shell Middle Distillate Synthesis process,gasoline from Mobil Methanol to Gasoline (MTG) process, diesel from the Mobil Methanol Olefins Gasoline Diesel (MOGD) process and finally gasoline from the same process. Some variation in production costs of all the products was shown depending on type of gasifier chosen and feedstock.