Gasifier Power Plant

Product Overview

Description

24 X 7 continuous operation. No daily shutdowns for filter cleaning or biochar removal.  Ash is the only waste. 

There are no Effluents. No Drainage. Water is re-circulated. 

There are no Emissions from the Plant.

The Gasification chamber, ash pan and hopper, are all made of Stainless Steel to prevent corrosion & has three times the life of MS generally prevalent. (It is even more than three times costlier than MS.)

No civil expenses for foundation are required for installation. Only a plain concrete surface is required.

A means for Green Energy….Gasification    

After a great effort, we developed this New Generation Multi-FuelGasification technology-Updraft Circulating Fluidized bed with direct & indirect Oxidation &specially designed Tar & dust separators to nullify TAR.

All types of feed stock viz. Biomass- Waste Wood, Saw dust, Bagasse, Rice husk, Coconut Shells, Algae, Agri-waste, Solid Waste- Poultry Litter, Thermocol, Waste Plastic, Rubber, Tires, Leather, Coal- Anthracite, Lignite etc can be used in our System.

Output of Single Unit: Up to 4 Mega Watts, single largest transportable unit. For higher capacities multiple Units will have to be commissioned.

Process: It is a thermo-chemical process of cracking at high temperature of 1100°C, in the minimal presence of Oxygen that converts solid waste, Biomass or coal to a gaseous fuel called Syn-Gas or “Producer Gas”.

The air being passed under pressure from the bottom through the vents of the cone in the Gasification chamber creates a fluidizing effect in the fuel inside to smother the gasification process and the circulation of the Ash Pan, creates a circulating effect in the fuel, with the result that the Gasification process of the fuel is enhanced.

Direct Oxidation: At this high temp. of 1100°C, Carbon combines with O2 to form CO, CH4, H2.  At lower temp. of 700°C, Carbon combines with O2 to form CO2.

Indirect Oxidation: Steam is co-generated in the Steam Jacket around the reactor & injected with air into the Reactor. At a high temp. of 1100°C, it dissociates into O2 & H2 to form more of CO & H2, resulting in further increase of efficiency of the system & also the calorific value of the Gas.

The Producer Gas from the outlet of Reactor is subjected to cleaning & cooling.

Cold Gas Mode: For Power Generation, or (thermal) Kilns of Ceramic Industry where colour of the product is important, the Producer Gas is subjected to several stages of washing & cooling. Initially, it is passed through venturi cyclones, pipe filters with multiple shower washers, then through the specially designed Tar & Dust separators & finally through the de-moisturizer for obtaining dry & ultra clean Gas, rich in energy with calorific value of more than 2000Kcal/nm3, to be a fuel for various applications viz.- Thermal Ceramic Kilns or Electricity Generating sets modified by us for Producer Gas mode of operation.  

Hot Gas Mode: For Thermal Energy-  The Producer Gas is passed through a cyclone to remove dust & soot. Tar is present in this gas in Vapour state at 400°C. This gas is directly injected into the Burners of Furnaces in Steel Mills, Kilns, Boilers for generating Steam for Green House heating or other Industrial use or Dryers, and Heat treatment equipment.

BENEFITS:

Ash is the only waste.No Effluents i.e. No Drainage. Water is re-circulated through cooling tower. No Emissions in the process.

By-Product:‘Tar’ with Cal.Val. 7400Kcal/kg obtained as byproduct. After centrifuging, it fetches 65%price of FO or can even be upgraded to Gasoline.

 Carbon Credits: 5000 Carbon Credits per MW per year can be availed & traded internationally.Value of One Carbon credit keeps on varying from 6€ to 20€ depending on the principle of demand & supply.

Co-generation: Waste Heat Recovery Boiler (WHR) at the exhaust of Engine, produces One Ton Steam/MW/hr. at 10 bar pressure OR Flue Gases can be utilized for drying of fuel also.

Flue gases are well within Pollution Control board norms, due to the complete direct firing of Producer Gas in the Engine.

Environment friendly Renewable Energy technology.   Very early payback period.

Downdraft Gasifiers:

• Down draft Gasifiers have low thermal efficiency at >50%.  
• Waste is Bio-Char having a residue energy of 20%, which is not fit for Furnace heating purpose & not suitable for landfill also.
• Low calorific value of Syn-gas at 950 Kcal. /NM3,
• High auxiliary Power consumption of 80KW per MW.
• High fuel consumption with <1.7Kg wood for 1KWH
• Cleaning of Filters, Removal of bottom waste i.e maintenance issues & shut down’s for the same, is a regular problem.
• Unable to operate 24 X 7
• Manufacture of capacities bigger than 400 KW is  unviable.

Updraft Gasifiers:

• Updraft Gasifiers are 98% efficient & further efficiency increased by H2 obtained from steam injected with air.
• Very low auxiliary power consumption at less than 20KW per MW.
• Low fuel consumption- 1 KWH generated by 0.8Kg. wood.
• No maintenance issues  viz. Removal of waste or cleaning of filters.
• 24 X 7 operation.
•  Waste is energy less ash.
• Single unit up to 4 MW can be manufactured.

Combustion   Vs   Gasification:

• CO2 produced on Gasification of 100 kg. Coal = 25.5 Cu. mt.
• CO2 produced on Burning of 100 Kg. Coal ……..=185 Cu. mt.  

• CO2 produced on Gasification of 100 kg. Wood..=19.2cu. mt.
• CO2 produced on Burning of 100 Kg. Wood………=139 cu.mt.

Combustion for STG (Steam Turbine Generator) Power Plant:

• For a Steam Turbine Generator, Coal / Bio-mass is Incinerated / Burnt, to fire the boiler for producing steam.
• CO2 is abundantly emitted, a major pollutant and responsible for increase of Green House gases & also of Global warming.
• Toxic gases emitted by the Burning of Plastics,  Polythenes, Waste Rubber, leather etc. with Heat & Energy loss as well.
• Sulphur, Chlorine & other contents in the feed stock form H2S, SO2, SO3, Cl, HCl, NOx, Dioxins & Furans. Chlorine Gas results in the formation of Acid Rain.
• The efficiency of STG is close to 23%. Rankine cycle & other co-generation modes are highly capital intensive
• With STG, 3800 to 4200KiloCalories are required to produce 1KWH.
• Heavy CAPEX.