Gasifier Integrated Boiler Based Power Plant–A boon for all scale industrial Sector to

meet thermal and power demand

Presented by

Mr. Sanjay Rao Chennamaneni, (Managing Director) Dr. Vinoth Kumar Kandasamy, (President – Technical)

CHOGEN POWERS PRIVATE LIMITED, Plot No.25, Phase-1, Paigah Colony,

S.P. Road, Secunderabad, Andhra Pradesh, India. Pin-500 003.

sanjay@chogenpowers.com

CHOGEN

Overview Combined draft gasification – An Introduction Our in-house design of one of the world's first commercially developed very high

temperature TAR FREE biomass gasifier is a combination of an up-draft and down-draft in a single reactor which could be operated under least pressure mode (300 mmWC) on multi-fuel biomass variety and higher size (up to 300 mm length X 200 mm Diameter) at extreme condition operatability (up to 35% moisture in the biomass) even with high ash content (up to 25%).

Combined draft gasification – Advantages Integration of the Combined draft gasification on co-firing into Boiler based

power plant Discussions on the operation of Combined draft gasification on co-firing into

Boiler based power plant CHOGEN's aim is to develop a fully automated operative gasifier system for

trouble-free & easy operation CHOGEN 2

Boiler Based 6 MWe Power Plant

Plant Commissioned in year 1999 (12 years age plant)

Boiler Installed capacity = 35 TPH (@ 65- 70% Efficiency)

Boiler Furnace Temperature around 800 °C

Steam Pressure @ 38 kg Pressure (450 °C)

Biomass Consumption@ 340 TPD (14.17 TPH)

In-house power consumption is around 15%

Biomass to Power Ratio is around 1:0.42

(1 TPH Biomass generates 420 kWe/hr that is 1unit of Power need – 2.4 kg of wood)

Biomass to Power generation cost is 5.50/- per unit

Fuel to Steam ratio is around 1:2 (1 TPH Biomass generates 2 TPH steam)

CHOGEN 3

Patented Designed Updraft based Down draft gasifier

CHOGEN 4

Updraft based down draft Gasifier 2TPH

Gasifier Commissioned in year 2012 (2 years age plant)

Installed capacity = 2 TPH (@ 85- 90% Efficiency)

Gasifier Combustion Zone Temperature around 1300 °C

Oxidizing agent – Atmospheric air – Pressure @ 300

MMWC

Biomass Consumption per day @ 48 TPD (2 TPH)

In-house power consumption is around 4%

Producer gas outlet temperature = 800 to 1000 °C

CHOGEN 5

Trails with Wood chip, Straw, Palm Trunk and Coconut Fronds

CHOGEN 6

Producer gas flame injected into the boiler

CHOGEN 7

Gasifier Coupled with Boiler Co firing

CHOGEN 8

A v e r a g e T e m p e r a t u r e i n ° C

Month Drying Flaming Pyrolysis Down Draft

Combustion Zone Gas outlet

Boiler Drum

Flue

Top Bottom

August – 2013 103.6 328.6 380.2 1316 898.9 784.7 694.2

September – 2013 104 327.15 367.4 1356.6 900.15 789.2 698.1

October – 2013 104.8 324.5 361.7 1475.6 906.1 791.7 702.5

November – 2013 105.4 324.8 367 1450.1 907.6 797.8 705.4

December – 2013 106.2 325.8 379.9 1395.1 907.16 799 708.1

January – 2014 106.8 326.6 388.9 1366.9 903.3 803.5 709.5

February – 2014 107.8 326.8 389.3 1269.9 900.6 804.8 711.7

March – 2014 108.7 331.15 389.7 1193.95 870.8 809.35 711.9

April – 2014 109.2 340.6 398.2 1112 850.8 812.6 712.7

May – 2014 110.2 350.2 427.3 1107.1 848.6 818.9 715.9

June – 2014 110.8 354.55 453.95 1196.6 902.1 819.2 713.8

July- 2014 112.2 357.1 470.3 1333.7 904.9 821.7 714.3

August – 2014 113.8 354.5 490.2 1334.1 907.6 821.4 715.7

September -2014 115.3 355.7 499.7 1227.65 890.6 824.35 713.1

Gasifier based boiler Performance tests -1

CHOGEN 9

Month

G a s i f i e r b a s e d B o i l e r A v e r a g e R e s u l t s T e m p e r a t u r e

°C Pressure kg/cm2

PGen MWe/day

Consumption Tons / day

Gas Outlet Boiler

Steam Steam Power Biomass

Left Right Gasifier Boiler

August-2013 626 546 480 417 24.16 144 48 190 September- 2013 671 559 536 459 22.78 140 45 160

October-2013 561 312 298 221 19.8 142 40 163 November-2013 512 326 299 200 23.6 141 43 155 December- 2013 671 569 532 450 23 140 42 158

January-2014 658 531 555 447 20 135 39 146 February-2014 616 473 450 365.67 22.22 140 42 156

March-2014 660 550 528 460 21.33 143 47 168 April-2014 655 546 556 428 20 142 50 176 May-2014 648 568 539 436 25.66 141 52 166 June-2014 780 620 598 478 29.66 144 50 170 July-2014 820 650 600 490 28 142 51 180

August-2014 800 635 567 525 30 143 49 167 September-2014 790 625 538 536 28 140 48 195

CHOGEN 10

Gasifier Alone Performance Tests - 2

G A S I F I E R P E R F O R M A N C E A V E R A G E R E S U L T S

Month Inlet Airflow rate

kg / hr

Outlet Gas flow rate

kg / hr

Biomass flow rate

Kg / hr

Power generation supported by gasifier

MW / hr

August-2013 3000 5000 2100 1.9

September-2013 2895 4798 2205 1.6

October-2013 2592 4500 2000 1.5

November-2013 3000 4995 2395 1.8

December-2013 2405 4389 1995 1.4

January-2014 2578 4675 2268 1.5

February-2014 2398 4281 1999 1.3

March-2014 2956 4886 2190 1.8

April-2014 2993 4995 2000 1.9

May-2014 2876 4996 2281 1.9

June-2014 3000 4999 2356 1.9

July-2014 3000 5000 2105 1.9

August-2014 3000 4990 2250 1.9

September-2014 3000 4885 2200 1.7

Time in flaming pyrolysis calculated from the equation

Cylindrical Volume Typical Dimension

Sphericity

Density Moisture Temp Oxygen Fraction

Length Flaming Pyrolysis

Time

V – cm3 D (cm) Fs ρ Fm ToC FO2 L tfp-min

Effect of Varying Dimensions - Leucaena long stick wood

6x6 169.6 5.53 1.8 0.5 0.25 600 0.21 6 9.605

12x5 235.6 6.17 1.8 0.5 0.25 600 0.21 12 5.836

24x6 678.5 8.77 1.8 0.5 0.25 600 0.21 24 5.535

68x5 1335.0 10.98 1.8 0.5 0.25 600 0.21 68 2.968

68x6 1922.6 12.40 1.8 0.5 0.25 600 0.21 68 3.728

Effect of Varying Temperature - 68 cm Leucaena long stick wood

68x6 1922 12.4 1.8 0.5 0.25 650 0.21 68 3.251

68x6 1922 12.4 1.8 0.5 0.25 700 0.21 68 2.876

68x6 1922 12.4 1.8 0.5 0.25 750 0.21 68 2.575

68x6 1922 12.4 1.8 0.5 0.25 800 0.21 68 2.330

68x6 1922 12.4 1.8 0.5 0.25 850 0.21 68 2.127

68x6 1922 12.4 1.8 0.5 0.25 900 0.21 68 1.956

68x6 1922 12.4 1.8 0.5 0.25 950 0.21 68 1.812

68x6 1922 12.4 1.8 0.5 0.25 1000 0.21 68 1.688

tfp = 0.207 ρFs (1+1.76Fm) D (1+ 0.61D) exp(4369/RT) / (1+ 3.46Fo2)

CHOGEN 11

Effects of superficial velocity and gas flow rates on the gasifier

CHOGEN 12

Effect of equivalence ratio for the gasification

CHOGEN 13

Wood particle temperature

CHOGEN 14

Producer gas flame

CHOGEN 15

CHOGEN 16

17 CHOGEN