Introduction:

Gasification is basically a technological process that involves the conversion

of carbonaceous (carbon based) raw material into synthesis gas using heat,
steam & pressure. This process involves the reaction of carbonaceous
feedstock with an oxygen containing reagent which may either be oxygen, air,
steam or carbon dioxide, generally at temperatures in excess of 800°C. This
process takes into account the partial oxidation of substance which means that
amount of oxygen is supplied in a limited way such that the fuel is not
completely oxidized and it causes combustion to not occur completely.
Although the process is largely exothermic, however, some heat is still
required to initiate the gasification process & to sustain it for effective
operation. The demand of Gasification systems is also increasing because they
are used to turn feed stocks like coal into useful chemical products like
ammonia.
Stages of Gasification:
The process of gasification takes place through four different stages
which are as follows:
1.Dehydration or drying
2.Pyrolysis
3.Combustion
4.Gasification
5.Equilibrium

1.Dehydration or drying:
The feedstock is dried before the gasification process and the moisture
extracted is used in later chemical reactions.
2. Pyrolysis:
In this stage, organic materials are thermo chemically decomposed at elevated
temperatures in the absence of oxygen which causes release of volatiles and
produces char. This prepares the chemically changed feedstock for combustion.
A carefully controlled burn using small amounts of air allows the volatiles and
the char to react with the oxygen to form primarily carbon dioxide, water and
trace amounts of carbon monoxide. The heat created in the process is used in
the gasification process.
3.Gasification:
The char reacts with the carbon dioxide and the steam produced in previous
steps to form carbon monoxide and hydrogen.
4.Equilibrium:
A chemical reaction known as the ―water gas shift reaction‖ helps to
balance the carbon monoxide, steam, carbon dioxide and hydrogen in the
gasifier establishing a chemical equilibrium during the final step of the
process.
There are two types of gasification on the basis of temperature.
• Low Temperature Gasification
• High Temperature Gasification

Gasifier:
A chemical reactor that converts feedstock (wood, biomass, coal) into
a combustible gas that can be used for:
• Heating Running an internal combustion engine
• Cooking
Types of Gasifier:
• Updraft Gasifier:
In this type of gasifier, the air is introduced at the bottom of the
gasifier from where it moves upwards & leaves from the top of the
gasifier. Near the grate at the bottom, the combustion reaction
occurs, which are followed by the reduction reactions .
• Downdraft Gasifier:
In order to find a solution of the problem of entrainment of tar in the
gas stream, the design of gasifier is changed from counter current to co-
current (down draft) gasifier, in which primary gasification air is
introduced at or above the oxidation zone in the gasifier. The producer
gas is removed at the bottom of the gasifier so that both fuel & gas move
in the same direction.
• Cross draft Gasifier:
This type of gasifier is adapted for the use of charcoal. Charcoal
gasification results in very high temperatures in the oxidation zones which can
lead to materials problem.
Benefits of Gasification:
• Syngas is cleaned before combustion which reduces air pollutants to the
atmosphere.
• Gasification enables the use of low-value feedstock (i.e., e.g. deep stranded
coal) to produce energy.
• Gasification plants use less water than coal combustion plants.
• CO2 can be cost-effectively captured from the gasification process.
• Syn gas can be used to produce electricity.
• Gasification systems are also increasingly being used to turn feed stocks like
coal into useful chemical products like ammonia.
• Limits the formation of dioxins & large quantities of SOx & NOx.
Disadvantages of Gasification:
• The process of gasification, although involves a lot of advantage, but it has
certain disadvantages:
• Tars, heavy metals, halogens and alkaline compounds are released within the
product gas and can cause environmental and operational problems.
• Tars are high molecular weight organic gases that ruin reforming catalysts,
sulfur removal systems, ceramic filters and increase the occurrence of
slagging in boilers and on other metal and refractory surfaces.
• Alkalis can increase agglomeration in fluidized beds that are used in some
gasification systems and also can ruin gas turbines during combustion
• Heavy metals are toxic and accumulate if released into the environment.
• Halogens are corrosive and are a cause of acid rain if emitted to the
environment.
Process description:

• The raw materials used in the manufacturing of syngas from biomass:

• Biomass (Rice Husk)

• Superheated Steam

• Air

• Process Water

• Selexol
1.BIOMASS SELECTION:
We have selected the average composition of biomass (rice husk) found
in different regions of Pakistan. The composition of biomass selected for
design purposes is as follows:

Biomass %
compi=osition

C 36.66

H2 4.37

O2 31.68

N2 0.23

S 0.04

H2 O 8.76

Ash 26.
2.PROCESSES INVOLVED:
The major steps involved in the formation of syngas from biomass are:

• Biomass Preparation
• Biomass Drying
• Gasification
• Gas Cooling
• Gas Purification

• CO2 Removal
• Compression of Syngas
3.PROCESS EQUIPMENTS:

• The major equipment’s used are as • Absorber

follows:
• Stripper
• Rotary Dryer
• Cooler
• Fluidized Bed Gasifier
• Compressor
• Waste Heat Exchanger
• Boiler
• Cyclone Separator
• Turbine
• Scrubber
• Knock out drum
4.BIOMASS PREPARATION:
Before rice husk can be introduced in the rotary dryer it is necessary to
pass it through some preparation steps e.g. it is necessary to remove dust
particles and other unnecessary material associated with risk husk for this
purpose screening is done by using specific sieves keeping in mind the average
particle size of rice husk is 1mm. In case of rice husk as particle size is already
quite small therefore further size reduction is not required.

5.BIOMASS DRYING:
Next step after preparation of biomass is drying of rice husk as it contains
8.76% moisture so it is necessary to reduce the moisture contents otherwise it
may cause problems in the gasifier specially in combustion process and will
make it difficult to maintain the stoichiometric ratio of biomass to steam in
gasifier and will also increase the load on heat exchanger used after gasifier.For
this purpose rotary dryer is used that reduces the moisture contents from 8.76%
to 2.80% and the operating efficiency of the rotary dryer is considered as 80%
6.GASIFICATION:
Now the rice husk is ready to be introduced in the gasifier. Gasifier used for
this purpose is Fluidized Bed Gasifier because it gives well mixing of the
biomass with oxidant. In our case it makes easier to control biomass and
oxidant amounts to be introduced and as rice husk contains large amount of
slag contents so it helps in to avoid the slagging of ash in the gasifier.

7.GAS COOLING:
Syn gas leaving the gasifier is at 800oC so it is necessary to remove
excess heat from it this is done by using a heat exchanger right after the
gasifier that reduces its temperature to 500 oC and serves the purpose of
preheating the boiler water as well. For this purpose shell and tube type heat
exchanger is used.
8.GAS PURIFICATION:
Syn gas produced contains large amount of ash contents, water vapors
and some quantity of unburnt rice husk so it is necessary to remove such
material from syn gas before it can be used as combustible gas. Solid particles
are removed by using a cyclone separator and a filter moisture contents are
removed by using a knock out drum.

9.SELEXOL SYSTEM DESCRIPTION:

The Selexol process uses a physical solvent to remove acid gas from the
streams of syngas. It is ideally suited for the selective removal of H 2S and
other sulphur compounds, or for the bulk removal of CO2. The Selexol process
also removes COS, mercaptans, ammonia, HCN and metal carbonyls.
3.1. Material Balance around Dryer:
• F2 61.32kg/h Solids 0% Water 100%
• Basis: 1000 kg/h of biomass feed
• Let the efficiency of dryer be 70%
• F2 = (F1) (% of water) (dryer efficiency)
• = (1000) (8.76%) (70%)
• F2 =61.32 kg/hr
• So, applying overall balance on Dryer
• F1 =F2 + F3
• F3 =F1 – F2
• =1000 – 61.32
• = 938.63 kg/h
• Applying component balance;
• Water balance:
• (x1) (F1) = (x2) (F2) + (x3) (F3) (0.0876)(1000) = (1) (61.32) + (x 3) (938.6) x3 = 0.028
•
 Inlet (Biomass) Outlet (Moisture) Outlet (Biomass) Streams F1 F2
F3 Flow rates (kg/h) 1000 61.32 938.68 C 36.66 - 39.06 H 4.37
- 4.66 O 31.68 - 33.74 N 0.23 - 0.25 S 0.04 - 0.04
H2O 8.76 - 2.8 Ash 18.26 19.45 3.2. Balance around Gasifier:
• F4
• (Air) 247.24 kg/h % O2 23 N2 77 F3 (Biomass) 938.68 kg/h % C 39.06 H2 4.66 O2 33.74 N2 0.25 S 0.04 H2O 2.8 Ash 19.45
• Basis: 938.68 kg of feed

• F7 (Syngas) 1318.914 kg/h % CO 33.031 CO2 23.316 H2 23.316 N2 14.5725 H2S 0.0291 Ash 5.7354

• F5 (Steam) 279.05 kg/h F6 (Ash) 182.57 kg/h % % Water 100 Ash 100
• Applying component mass balance:
• 3906)(938.68) = (ωco) (F7) + (ωCO) (F7)
• 366.65 = (ωCO + ωC02)F7……………… (1)
• (0.0466 + 0.028)(938.68) + (1) (F5) = (ωH2 + ωH2S) (F7)
• 70.03 + F5 = (ωH2 + ωH2S) (F7)……….. (2) O2 Balance:
• (0.3374 + 0.014) (938.68) + (0.23) (F4) + (1/2) F5 = (1/2 ωCO + ωCO2) (F7)
• 329.85 + 0.23F4 + 0.5F5 = (0.5ωC0 + ωCO2) (F7)…………. (3) N2 Balance:
• (0.0025)(938.68) + (0.770 (F4) = (N2) (F7)
• (0.04/100) × (938.68) = (H2S) (F7)
• 0.375 = (H2S) (F7)……………………………………….. (5)
• Ash Balance:
• (0.1945) × (938.68) = (1) (F6)
• F6 = 182.57kg/ h ash
• Chemical Reaction
• 2.03C + 1.03 H2O + 0.5 O2 2.03CO + 1.03H2

• Air Required:
• 0.3906×938.68 kg/h C 1 kgmol/h C 0.5 kgmol/h O2 12 kg/h C 2.03 kgmol/h C
• O2 required = 7.53 kgmol O2
• Air required = Moles of O2 + Moles of N2
• = 7.53 + 1
• = 8.53kgmol air
• F4 = 247.24 kg/h air

• Steam Required:
•

• 0.3906×938.68 kg/h C 1 kgmol/h C 1.03 kgmol/h H2 O 1 kgmol/h H2O 12 kg/h C 2.03kgmol/h C 1 kgmol/h H2O
• F5= 279.05 kg/h steam
• Applying overall material Balance
• Mass in = Mass out
• F3 + F4 + F5 = F6 + F7
• F7 = F3 + F4 + F5 - F6
• 938.68 + 247.24 + 279.05 - 182.57
• F7 = 1282.4 kg/h syn gas
• Put value of F7 in equation 5;
• 0.375 = (H2S) (1282.4)
• H2S = 0.03
• Put value of F7 & F4 in equation 4;
• 2.35 + 0.77(247.24) = (N2) (1282.4)
• N2 = 0.15
• Put value of F5 H2S & F7 in equation 2;
• H2 = 0.24 As we know that ωCO + ωCO2 + ω N2 + ω H2S + ωH2 = 1 ωCO + ωCO2 + 0.15 + 0.03 + 0.24 = 1 ωCO + ωCO2 = 0.58
• OR
• ωCO = 0.58 - ωCO2 ……………………………………….. (6)
• Putting values of ωCO, F4, F5 and F6 in equation (6)
• 329.85 + 0.23(247.24) + 0.5(279.05) = (0.5(0.58 - ωCO2) + ωCO2) (1282.4)
• 0.41 = 0.29 – 0.5ωCO2 + ωCO2 ωCO2 = 0.24
• Put the value of ὠCO2 in equation (6) ωCO = 0.58 – 0.24 ωCO = 0.34
• From literature, 20% of Ash goes into syngas. So F4 will be:
• F4 = 146.056 kg/h
• Amount of gas coming out of gasifier = F7 + 20%Ash
• =1282.4 + (20%) (18 2.57)
• F7 = 1318.914 kg/h

• INLET OUTLET Stream F9 F4 F5 F6 F7 Flow rates 938.68

• (kg/h) 247.24 (kg/h) 279.05 (kg/h) 146.06
• (kg/h) 1318.914
• (kg/h) Component
% C 39.06 - - - - H2 4.66 - - - 23.34 N2 0.25 77 - -
14.58 O2 33.74 23 - - - Ash 19.45 - - 100 2.77 H2O
2.8 100 - - CO - - - - 33.06 CO2 - - - - 23.34 H2S
- - - - 2.92
3.3. Material Balance around Cyclone
Separator:
•

• Flow rate of syngas in = F9 = 1318.914 kg/h

• Flow rate of syngas out = F11 =? kg/h
• Flow rate of Solids outlet = F12 =? kg/h
• Assume,
• Efficiency of Cyclone separator =80 % = 0.8
• So, the flow rate of outlet solids is,
• F12 = (Efficiency of Separator) × (Flow rate of Syngas in) × (%age solids in syngas)
• F12 = 0.8 × 1318.914 × 0.028
• F12 = 29.54 kg/h
• So, for syngas outlet,
• F11 = F9 – F12
• F11 = 1318.914 – 29.54
• F11 = 1289.37 kg/h
• INLET OUTLET Stream F9 F12 F11 Flow rates 1318.914 kg/h 29.54 kg/h 1289.37
kg/h
 Component % H2 23.34 - 23.834 N2 14.58 -
14.935 Ash 2.77 100 0.572 CO 33.06 - 33.858
CO2 23.34 - 23.834 H2S 2.92 - 2.967 3.4.
Material Balance around Separator:
• F14
•

• It is now considered that the scrubber will remove remaining solids present in the syngas.
• Solids present in Syngas = 0.572% of F11 = 7.38 kg/hr
• Amount of syngas = F11 = 1289.37 kg/hr
• Solids removed = F13 =7.38 kg/hr
• Amount of cleaned syngas = F12 = 1282 kg/hr

• INLET OUTLET Stream F11 F13 F14 Flow rates 1289.37 kg/hr 7.38 kg/hr 1282 kg/hr Component
% H2 23.834 - 24 N2 14.935 - 15 Ash
0.572 100 0 CO 33.858 - 34 CO2 23.834
- 24 H2S 2.967 - 3 4.1. Energy Balance around Dryer:
• Calorific value of biomass in F =32660 KJ/kg
3

• Specific heat of air at T = CP01 =1KJ/kg

01

• Specific heat of air at T = CPA =1KJ/kg

02

• Specific heat of water at T = CPW =4.18 KJ/kg

2
HEAT IN
• By Biomass

•Q = F1 × C.V
1

• = 1000 × 16885.7/3600
• = 4690.47 KW
• Air

• Q01 = F01 × CP01 × ∆TF

• =F01 × 1 × (343-298)
Q1 = 45F01 kW
HEAT OUT
• By F2
• Q2 = F2 × CP2 × ∆TF2
• CP2 = (CPA + CPW)/2
• = 2.59 KJ/kg-k
• Q2 = (F1 + 61.32/3600) (2.59) (303 – 298)
• Q2 = 12.95 (F1 + 0.017)
• Total heat in = Total heat out
• 4690.47 + 45F01 = 12.95 (F01 + 0.017) +8515
• F01 = 119.34 kg/s
• F01 = 429613 kg/h
• Then,
• F02 = 429674.42 kg/h
• Q1 = 5370.3 kW
• Q2 = 1545.67 kW
• HEAT LOSSES = (Q1 + Q2) – (Q3 + Q4)
4.2. Energy Balance around Gasifier:
• Mass flow-rate of Biomass = F = 938.68 kg/h
3

• Temperature of Biomass = T = 50°C = 323K

3

• Reference temperature of Biomass = T = 25°C = 298K

r

• Specific heat capacity of Biomass = C = 1.926 kJ/kg-K

p

• Energy entering in gasifier from Biomass = F × Cp × (T3-Tr)

3

• Energy entering in gasifier from Biomass = 938.68 × 1.926 × (313-298)

• Energy entering in gasifier from Biomass = 45197.44 kJ/h

4.2.2. Energy in Air:
• Mass flow-rate of Air = F = 247.24 kg/h
4

• Temperature of Air = T = 304.8°C = 577.8K

4

• Reference temperature of Air = T = 25°C = 298K

r

• Specific heat capacity of Air = C = 1.073 kJ/kg-K

p

• Energy entering in gasifier from Air = F × Cp × (T4-Tr)

4

• Energy entering in gasifier from Air = 247.24 × 1.073 × (577.8-298)

• Energy entering in gasifier from Air = 74227.73 kJ/h

• Energy entering in gasifier from Air = 74227.73 /3600

• Energy entering in gasifier from Air = 20.61 kW

4.2.3. Energy in Steam:
• Mass flow-rate of Steam = F5 = 279.05 kg/h
• Temperature of Steam = T5 = 400°C = 673K
• Reference temperature of Steam = Tr = 25°C = 298K
• Specific heat capacity of Steam = C p = 2.083 kJ/kg-K
• Latent Heat of Vaporization = λ = 2350 kJ/kg
• Energy entering in gasifier from Steam = F5 × [Cp × (T5-Tr) + λ]
• Energy entering in gasifier from Steam = 279.05 × [2.083 × (673-298) + 2350]
• Energy entering in gasifier from Steam = 873740.4 kJ/h
• Energy entering in gasifier from Steam = 873740.4/3600
• Energy entering in gasifier from Steam = 242.71 kW
• Total Energy In = Energy in Biomass + Energy in Air + Energy in Steam
• = 12.55 + 20.61 + 242.71
• Total Energy In = 275.87 kW
• Total Energy Generated = F3 × Cp × (T7 – T3)
• Total Energy Generated = 938.68 × 1.926 × (1073 – 323)
• Total Energy Generated = 1355923.26 kJ/h
• Total Energy Generated = 1355923.26/3600
• Total Energy Generated = 376.65 kW
• Total Energy Out = Energy in Ash + Energy in Flue Gas
• Mass flow-rate of Ash = F6 = 146.06 kg/h
• Temperature of Ash = T6 = 800°C = 1073K
• Reference temperature of Ash = Tr = 25°C = 298K
• Specific heat capacity of Ash = C p = 0.514 kJ/kg-K
• Energy leaving gasifier with Ash = F6 × Cp × (T6-Tr)
• Energy leaving gasifier with Ash = 146.06 × 0.514 × (1073-298)
• Energy leaving gasifier with Ash = 58183 kJ/h
• Energy leaving gasifier with Ash = 58183/3600
Energy leaving gasifier with Ash = 16.16
kW
4.2.5. Energy in Syngas:
• Mass flow-rate of Syngas = F7 = 1318.914 kg/h
• Temperature of Ash = T7 = 800°C = 1073K
• Reference temperature of Ash = Tr = 25°C = 298K
• Specific heat capacity of Ash = Cp = 2.22 kJ/kg-K
• Energy leaving gasifier with Ash = F7 × Cp × (T7-Tr)
• Energy leaving gasifier with Ash = 1318.914 × 2.22 × (1073-298)
• Energy leaving gasifier with Ash = 2269191.537 kJ/h
• Energy leaving gasifier with Ash = 2269191.537/3600
• Energy leaving gasifier with Ash = 630.33 kW
• Total Energy Out = Energy in Ash + Energy in Syngas
• = 16.16 + 630.33
• Total Energy Out = 646.49 kW
• 4.2.6. Overall Energy Balance:
• Energy Loss = Total Energy in – Total Energy Out + Total Energy Generated
• Energy Loss = 275.87 – 646.49 + 376.65
• Energy Loss = 6.03 kW
4.3.1. For Syngas:
• Flow rate of syngas in = F = 1318.914 kg/h
7

• Temperature of syngas in = T = 800°C = 1073K

7

• Flow rate of syngas out = F = 1318.914 kg/h

8

• Temperature of syngas out = T = 500°C = 773K Specific heat capacity of

8
syngas = Cps = 2.22 kJ/kg-K
4.3.2. For Water:
• Flow rate of water in = F9 = x kg/h
• Temperature of water in = T9 = 25°C = 298K
• Flow rate of water out = F10 = x kg/h
• Temperature of water out = T10 = 98.55°C = 371.55 K
• Specific heat capacity of water = Cpw = 4.18 kJ/kg-K
• Applying energy balance on heat exchanger
• Energy in (Gas) + Energy in (Water) = Energy out (Gas) + Energy out (Water)
• In mathematical form,
• (F7×Cps×T7) + (F9×Cpw×T9) = (F8×Cps×T8) + (F10×Cpw×T10)
• As F7 = F8 = 1318.914 kg/h and
• F9 = F10 = x kg/h
• So the equation can be written as
• (F7×Cps×T7) + (F9×Cpw×T9) = (F7×Cps×T8) + (F9×Cpw×T10)
• Or
• F7 × Cps × (T7 – T8) = F9 ×[Cpw × (T10 – T9)]
• Putting values,
• 1318.914 × 2.22 × (1073 – 773) = x × [4.18 × (371.55 – 298)]
• x = 2857.141 kg/h
• So,
• F9 = 2857.141 kg/h
• F10 = 2857.141 kg/h
• So, heat in gas,
• Qs = F7 × Cps × (T7 – T8)
• Qs = 1318.914 × 2.22 × (1073 – 773)
• Qs = 878396.724 kJ/h
• Qs = 878396.724/3600
• Qs = 244 kW
• So, heat in gas,
• Qw = F9 ×[Cpw × (T10 – T9)]
• Qw = 878396.57 kJ/h
• Qw = 244 kW
• Energy Balance Around Heat Exchanger Energy In Stream Flow rate
• (kg/hr) Cp (kJ/kg-K) T(K) Q = F × Cp × (T-Tr) Syngas 1318.914 2.22 1073 630.33 Water 2857.141 4.18 298 0 Total Energy In = 630.33 kW Energy Out Stream Flow rate