Technical difficulties in operating stand alone gasification systems: Role of

design parameters and practical solutions

Bhaskar Dahal*, Bivek Baral , Sumit Karki
Gasifier Engine Research Lab , Department of Mechanical Engineering
Kathmandu University
*bhaskar.dahal@gmail.com

Abstract

Around 60% of population of Nepal are devoid of electricity, most of which are from rural areas. For
places where electrification through national grid connection and micro hydro is not technically and
economically viable, community electrification via standalone gasification plants can be an option for
providing basic access to electricity to those communities using agricultural or forest residues generated
within the vicinity. For efficient and trouble free operation of gasifier plant, the understanding of social,
economical , technical and operational aspects within the beneficiary community is crucial for gasifier
acceptance and successful implementation of gasifier plant for community electrification .

Besides proper biomass supply chain management, detail technical aspects of operation and maintenance
cannot be undermined while operating the gasifier plant . A small operational alternation from the
specified procedure can increase down time of the plant. Moisture content beyond the designed range
can adversely affect the quality of syngas and can generate more tar, which can hinder proper engine
operation and reduce its reliability and durability. Further, bridging problems which is associated with
basic fuel size can stop the gasification process thereby shutting down the whole system till proper
maintenance of the gasifier is carried out . Similarly, biomass composition has also greater impact on the
engine performance as the quality of syngas generated depends upon it .These simple parameters have
great impact on operation of gasifier and acceptance of the technology. This paper intends to discuss the
effect of vital parameters like moisture content, fuel size, equivalence ratio and gas conditioning and
technical difficulties arising from lack of basic understanding in operation of gasification plant in rural
areas. Furthermore, practical methods of encountering technical problems are presented, focusing on
rural communities of Nepal.

1. Background:
Biomass-gasification is a non conventional
renewable energy technology, which has been in
use for thermal and electrical power generation
at various places and industries throughout the
world. Besides thermal power generation, this
technology can be used in electricity generation
using dual fuel engines, Spark ignition engines,
gas turbines or steam turbines. Considering the
components and accessories, cost, technical
aspects and ease on handling and operation,
engines running on dual fuels are suitable to use
in small scale operation.
This technology and has been used for rural
electrification in various places all over the
world and is an attractive technology for
community electrification in developing Asian
countries like India, Cambodia, Thailand,
Nepal[1]. For country like Nepal whose major
energy resource is biomass, mainly fuel wood
[2], gasification technology is most suitable in
energy conversion and electrification of rural
areas which are far off national grid and other
options like micro-hydro and wind power are not
feasible. Gasification not only saves the
declining status of forests but also can utilize the
residues from agriculture and forest for better
purpose. The core advantage of this technology
is, that it can be designed being based on
practical aspects of site of interest.
A gasification plant basically comprises of a
reactor, gasifying system and a conditioning
system. For a small plant, gasifying systems are
generally suction or blowing type.
A suction system uses components like Jet-
ejector (Figure 1a) where water is employed as
primary fluid which creates sufficient pressure
difference so as to derive the gas generated
inside the reactor. Second type of gasifying
system is a blowing system, where a rated
blower is use to supply continuous blast of air
for gasifying.
Gas conditioning systems are used in order to
clean and cool gas as per permissible limit of
engine. Wet type conditioning system uses water
as fluid and components like hydro-cyclone
(Figure 1b); Filters (Figure 1c, 1d) are used.
Main function of hydro cyclone is to separate
bigger sized particulates from gas stream, also
cooling of gas is accomplished. Filters are used
to trap the condensed tar and absorb remaining
particulates if any. A dry type conditioning uses
cyclone whose work is to separate bigger sized
ash particulates from the gas stream. Heat
exchangers (Figure 1e) are employed for gas
cooling. Like wet type system filters are used to
absorb condensed tars and small sized
particulates.
Though great many advances have been made in
huge capacity commercial gasification plants,
there are still problems in designing and
operating small scale plants used as standalone
operating systems in developing countries.
Various aspects must be considered while
designing or selecting gasifiers. A gasifier plant
can operate on its best if design is carried as per
real scenario based on detail feasibility study of
the site. Aspects like type and availability of
biomass and water resources availability for
selection of wet or dry type system play crucial
role in selecting type and size of gasifiers.
While operating a standalone system, the
beneficiary community is likely to face
problems ranging from biomass management,
resource and financial management and
technical setbacks.
Lack of proper operational knowledge of the
system is likely to increase the downtime of
plant operation which has effect upon then status
of the plant. Biomass resource allocation,
transportation, storage and preprocessing are
first steps of gasification. On operation various
technical problems are likely to arise, which are
basically associated with fuel, gasifying agent
and conditioning process. In sections below,
parameters of gasifier selection, aspects of
biomass resource management, system operation
and methods of tackling technical problems
associated with the systems are discussed.
 Fig 1d: Rice husk filter [3]

Fig 1a: Jet ejector (Source: Wikipedia)

Fig 1e:Heat exchanger

2. Key issues related to technical

difficulties
2.1 Gasifier selection
a. Throat size
The selection of gasifier must be done
on the basis of availability of the fuel. If
Figure 1b: Hydro-cyclone
the generally available fuel size is large
such as woods, twigs, molasses, the
throat size should be large. If the fuel
size is small such as rice husk, saw dusts
etc. the throat must be small.

b. Hopper size and geometry

Flowablity of fuel is crucial for
continuous operation of gasifier. For
fuels which are on average spherical,
cylindrical hopper can be considered.
Those fuels which are asymmetrical,
Fig 1c: Fabric filter[3] long and randomly shaped conical type
of hopper works better. Mechanisms
like eccentric motor which create
vibration in hopper are generally fitted
on the hopper to ensure smooth flow of
the fuel.
 c. Ash agitating mechanism
In the reaction zone, the fully combusted
fuels form ash and are likely to block
the flow of produced gas. Ash agitating
mechanism is used to ensure that the
flow of the gas is continuous. There are
two types of ash agitating or grate
shaking mechanism. A mechanism with
motor eases the operation, but it requires
either battery which acts as a parasitic
load. Mechanical mechanisms are also
employed, but the ease of operation is
compromised.
2.2. Biomass Resource management
Improper biomass resource management can
create problems in sustainability.
Sustainability is related with socio-economic
and environmental aspects of the site. A well
thought out biomass supply chain will keep
a more constant and reliable feedstock for
the gasifier system and thus ensuring good
availability of the plant throughout the
year. The foremost consideration for
sustainable biomass supply is that the
biomass resources should be raised and
protected in certain dedicated area[3].
Depending upon the geo-environmental
status of the site, various types of plants can
be selected and planted. Harvesting must be
carried out in same pattern. The size of
plantation area can be determined from the
biomass consumption rate of the plant and
yield of biomass per unit area per unit time.
To ensure proper supply chain and
encounter any uncertainty, it is better to
plant multispecies of biomass[3].
Transportation, storage and preprocessing
are other crucial factors of biomass
management. There must be a proper
management to transport the raw biomass
from harvesting site to the storage or
processing site. Thus collected fuel must be
sundried, until it reaches permissible limit
of moisture for gasification, which is
normally around 10-15%. Preprocessing
tasks like preparing the biomass as per fuel
size specification of the gasifier must be
carried out. The storage capacity of the
warehouse must be enough so as to
continuously supply biomass for about 3
months or to a certain amount that ensures
continual operation even incase raw biomass
in not available for certain period of time.
2.3. Technical parameters influencing
operation
a. Fuel size: The size of biomass being fed
to the gasification system has large influence
in operation and gas production. Though
smaller size wood are likely to produce
more amount of gas, very small size of
biomass can cause huge amount of ash and
clogging in the reduction zone.
Similarly very large size biomass can cause
low generation of producer gas and might
cause clogging in the hopper. Thus fuel size
must be in permissible range of used
gasifier.
b. Equivalence ratio:
Equivalence ratio in gasification process is
defined as:
The basis of gasification is to supply less
oxidant than would be required for
stoichiometric combustion of solid fuel. The
energy value of syngas is 75% of chemical
heating value of typical solid fuel[4].
The equivalence ratio differs from fuel to
fuel as each biomass is unique in
composition, which changes the requirement
of air for complete combustion.
c. Moisture content:
Although higher moisture content has
negative influence on gasification, as it
produces carbon dioxide in higher volume,
very low moisture content too has negative
effect on production of hydrogen gas which
is major component while using syngas as
fuel.
With increase in moisture content 5 wt% to
20 wt %, mole fraction of hydrogen
increases from 0.163 to 0.194, but the
production of carbon dioxide increases too
[5]. It is therefore processed biomass must
be within range of 10-15% so that neither
huge amount of carbon dioxide is formed
nor low content hydrogen is produced.
d. Temperature:
Generally the gasification occurs from the
temperature range of 650-700C. It is
therefore moisture content and equivalence
ratio must be considered to achieve desired
range of temperature. With increase in
temperature, share of hydrogen and carbon
monoxide in syngas increases and methane
and carbon dioxide share decreases, which is
due to facilitation of water gas reaction at
high temperature[6]. Higher temperature
above 1000C is not desired because it
causes ash melting and slag formation inside
the gasifier.
e. Conditioning:
As discussed earlier, there are two types of
conditioning systems. Wet type system that
uses water as motive fluid and cleans and
cools the gas and dry type system that uses
blower for air supply and cleaning is
accomplished with the help of cyclone and
filters.
The conditioning system must be good
enough to clean out the ashes, particulates
and tars, and the gas at the exit of the whole
system must be free of particulates or must
be within permissible range for engine
operation.
3. Problems in standalone system
and solutions
a. Fuel clogging:
Clogging of fuel in the hopper section is
generally due to large size of fuels or small
hearth size. Either way, the fuel size is not
suitable for the system.
In order to prevent fuels from clogging,
optimized fuel size as specified by the
gasifier manufacturer must be used.
Eccentric motor that causes vibration in the
hopper can also help in smooth flow of the
fuel, but this increases parasitic load, thus
this type of system is desirable only in
bigger sized gasifier, mechanical system is
effective and efficient for smaller systems..
b. No primary Ignition:
While operating, sometimes problem like
difficulty in ignition occurs, which is likely
to be caused by fuel with high moisture
content, lack of charcoal in the combustion
zone or no flow of fuel to the region.
Mitigation of this problem can be done by
using fuel with appropriate size and low
moisture content.
Another probable cause of this problem can
be blockage in air nozzles if any. In such
case airways in nozzle must be cleaned.
c. Low gas flow:
Flow of gas can be lower in case, if there is
restriction in pathway of gas carrier. Gas
carriers like pipes must be checked. Another
probable cause can be low flow of gasifying
agent. If such problems are diagnosed,
suction system must be checked if system is
wet type or blower system must be checked
if it is dry type, in order to ensure proper
flow of gasifying agents.
In order to mitigate this problem,
manufactures must provide systems with
arrangements to check pressure drop. Higher
the pressure drop, more the restriction in the
flowing channels. Regular checkup and
maintenance, and cleaning of auxiliary
systems like pipes, and filters must be
carried out in timely basis.
d. No ignition during flaring:
While carrying on flaring test, the producer
gas might not ignite which can be due to
high volume of carbon dioxide, resulting
low volume of carbon monoxide, caused by
low temperature gasification and high
moisture content. To encounter this
problem, operators must ensure proper
moisture content of the fuel. Appropriate
insulation of the combustion zone can also
facilitate to increase in temperature.
e. Higher amount of ash formation:
Generally, the combustion of stem wood
does not involve any large ashrelated
problems. This is mainly due to that the
total level of ash forming elements are low.
The relative composition can be problematic
though, since the concentrations of alkali
metals, sulfur and chlorine are relatively
high.
If more external parts of the forest biomass
such as bark, branches, tops, needles and stu
mps are included, the ash content increases
significantly and hence the risk of ash
related problems[7].
Besides, woody biomass the property of
some fuels, like rice husk, which generate
higher quantity of ash, frequent grate
agitation etc. can also cause higher amount
of ash formation, which in turn decreases the
reaction temperature and quality of syngas.
It is therefore, for larger and continual
operation, timer controlled motors should be
used. For operation of short time (usually 3-
4 hours) grate agitation must be carried only
when the flow of gas is decreased or can be
carried out in intervals of an hour.
f. Increased amount of tars:
Low temperature gasification systems are
likely to generate increased amount of tars,
which are likely to occur due to high
moisture content or presence of higher
amount of lignin content in the biomass.
Higher quantity of tar in gas stream can have
hazardous effect on the engine operation and
is likely to increase downtown of the
system. In order to ensure smooth operation,
better cooling and cleaning system
compromising or either hydro cyclones and
filters or cyclones, heat exchangers and
filters must be used.
The materials used in filters must be
changed on regular basis, depending upon
the nature of filters and its capacity to
capture tar.
4. Conclusion:
Though, gasification technology is
technically proven and has been successfully
implemented in large commercial scales,
there are hindrances while using this
technology in rural areas, especially when
used as standalone system.
Several challenges must be faced, in order to
successfully implement this system. Aspects
like biomass management, technical
operation and maintenance must be properly
taken under consideration. Key personnel of
beneficiary community must be properly
trained on management related aspects and
issues. Technicians and operators must have
training on gasifier and engine operation [7] Zevenhoven, Maria. 'Ash Forming
and maintenance. Timely maintenance of Matter In Biomass Fuels'. Ph.D. Abo
system must be carried out. Academi University, 2001. Print.
Rural electrification via gasification
technology has large scope in developing
countries, but careful planning and operation
is the key aspect of success of these projects.

Bibliography:
[1] Water and Energy Commission
Secretariat,. Energy Consumption Situation
In Nepal (Year 2011/12). Kathmandu:
Government of Nepal, 2014. Print

[2] AIT,. Report On The Status Of Biomass

Gasification In Thailand And Cambodia.
AIT, 2010. Print.

[3] A Study Of "Sustainable Operation Of

Biomass Gasifier" At Madhubangoth VDC,
Sarlahi. Renewable Energy for Rural
Livelihood (RERL), 2012. Print.

[4] Doherty, Wayne, Anthony Reynolds, and

David Kennedy. 'The Effect Of Air
Preheating In A Biomass CFB Gasifier
Using ASPEN Plus Simulation'. Biomass
and Bioenergy 33.9 (2009): 1158-1167.
Web.

[5] Sheth, Pratik N., and B.V. Babu.

'Experimental Studies On Producer Gas
Generation From Wood Waste In A
Downdraft Biomass Gasifier'. Bioresource
Technology 100.12 (2009): 3127-3133.
Web.

[6] Marek, Balas, Lisy Martin, and Jiri

Moskalik. 'Temperature And Pressure Effect
On Gasification Process'. In Advances in
Fluid Mechanics & heat & Mass Transfer
(2012): 198-202. Print.