biomass gasification: success stories and lessons … · gasifier for co 2 making, gujarat...

Biomass Gasification:Success Stories and

Lessons LearnedV V N Kishore

Senior Fellow, EET DivisionThe Energy and Resources Institute (TERI)

New Delhi, India

Presented at IEA Bioenergy Agreement, Task 33Fall 2006 meeting at GTI

31 October 2006

M L Sharma

L B Thakur

E Joseph

U Vellaikannu

Rajkumar

Dilip Sharma

V V N Kishore

Sunil Dhingra

Sanjay Mande

P Raman

Gaurav Mishra

Kusum Lata

N K Ram

Mohit Pushp

TechniciansProfessionals

Gasifier Team at TERI

Puffed rice (D, U)Other Fuels(tyres/rice husk)

Sweet making (D)LPG

Water heaters inhostels (D)

Electricity

Crematoria (D)Rubber drying (D, U)Canteens (D)Bakeries (D)

Silk dyeing (D)Diesel/Furnace Oil

CO2 manufacturing (D)Charcoal

Community cooking(D)Residential Hostels (U,ND)Crematoria (D)

MgCl2 (U)PoP (U, D)Tobacco curingMyanmar (D)Green brick drying(ND)Bamboo mat factory(U)

Silk (D)Cardamom in India,Nepal, Bhutan (ND)Arecanut processing(D)

Wood

COMMUNITYSMALLMICROENTERPRISE TYPEWood/coconut

shells/cashewshells/stalks etcreplacing

Comparative energy costfor different fuels

(For Quseful = 10 000 kcal/hr)

0 20 40 60 80 100

Electricity

LPG

Diesel

Coal

Charcoal

Wood traditonal

Wood (woodgas)

RS

0.00 0.50 1.00 1.50 2.00 2.50

USD

Approximate Initial Gasifier Costs andPayback Periods for different fuel replacements

ReplacingLPG

ReplacingDiesel

ReplacingWood

2.5

(0.33)

2.86

(0.21)

5

(2.78)

50000

(1111)

10 kg/hr

5.0

(0.33)

5.71

(0.21)

10

(2.78)

100000

(2222)

20 kg/hr

Note: * USD = 45 Rs, *** Operation assumed: 8 hr per day, 25 days per month

25.0

(0.17)

28.57

(0.10)

50

(1.39)

250000

(5556)

100 kg/hr

10.0

(0.29)

11.43

(0.18)

20

(2.43)

175000

(3889)

40 kg/hr

Fuel replaced

(Simple payback in years***)

Cost in

Rupees

(USD*)

Capacity

(Updraft)

Approximate Initial Gasifier Costs andPayback Periods for different fuel replacements

ReplacingLPG

ReplacingDiesel

ReplacingWood

2.5

(0.50)

2.86

(0.31)

5

(4.17)

75000

(1667)

10 kg/hr

5.0

(0.50)

5.71

(0.31)

10

(4.17)

150000

(3333)

20 kg/hr

Note: * USD = 45 Rs, *** Operation assumed: 8 hr per day, 25 days per month

25.0

(0.30)

28.57

(0.19)

50

(2.50)

450000

(10000)

100 kg/hr

10.0

(0.42)

11.43

(0.26)

20

(3.47)

250000

(5556)

40 kg/hr

Fuel replaced

(Simple payback in years***)

Cost in

Rupees

(USD*)

Capacity

(Downdraft)

Wood gas basedsilk reeling cottage basin oven

Importance/relevance:• 1.7 lakh people dependent on reeling• more than 25,000 cottage based units• Low income: Rs. 40 & 25/day for reeler & labour• Low yield, low productivity, low efficiency (<15%)• Low profit-margin, high energy intensity• Smoky working conditions; high health hazards

Wood gas basedsilk reeling cottage basin oven

Large cardamom drying

• India: largest (54%) producer in world 4000 MT/yr• Sikkim contributes more than 88%• Large cardamom is major cash crop of Sikkim• Cardamom is small farmers business

(more than 85% with small <2ha area)• Still primitive smoking method used for curing

resulting in poor quality product• Traditional bhatti system: low (5--10%) efficiency:

huge fuel wastage (estimated wastage: 20,000 MT in Sikkim)

Challenges to develop an appropriate system• can be fabricated locally• can be operated without electricity• can be transported in hilly terrain• is affordable to small marginal growers

Product development

Use of tandooras updraft gasifier

Improved “Mark 2” systemTrial field testing of“Mark 0” system at Kabi

“Mark 1” system

Systemperformance

Strengths of product& financial viability

• does not need electricity for operation• transportable in hilly terrain• can be fabricated locally• more than 60% fuelwood saving• retains 35% more volatile oil• retains natural colour (better appeal)• good aroma of volatile oil• pays back itself in one curing season

Gasifier-based dyeing unit

Salient features• Reduces the firewood consumption by more than 50%• One time fuel feed, for 5-hour continuous batch operation• Good control of the “liquor temperature”• Biomass briquettes can also be used as fuel• Replaces petroleum fuels (kerosene, diesel), wherever used

Demonstration of a biomass-gasifierbhatti at Jaipur

• Namkeen units use diesel forNamkeen making

• Gasifier system of 40 kg/hcapacity intervention has beenable to save conventional fuel(diesel) of the order of 11 l/h.

• Economic benefit: with aninitial investment of Rs 2.75lakhs, the industry has beenable to saves Rs 2400 per daywhich translate into payback ofjust less than 120 days.

• Reduction in GHG emission

Gasifier Installation at AjmerShariff

Gasifier based arecanut boiling systemTraditional Boiling System

Arecanut processing in Assam

Traditional bhatti

Amount of nuts 120-140 kg

Time for boiling 2-2.5 hr

Total curing time 4- 5 hours

Wood consumption 100-125 kg

Gasifier based system

Amount of nuts: 140 kg

Time for boiling 1 hour

Total curing time 3 hrs

Fuel consumption 45 kg

Arecanut shell tried in gasifier & encouraging results obtained

Savings of fuel: 50 – 70% ( for both wood and shell)

Fuel saving benefit was enhanced by supplying hot clean fluegases from arecanut boiling bhatti to drying chamber and the

quality of dried nuts was also found better

Field Results

Puffed Rice making, Karnataka

Rubber Tyres as fuel for the industry

Retrofitted gasifier in existed ovenPuffed rice making

Manufacture of Magnesum Chlorideat Kharagoda, Gujarat

• Replaces more than 100 year age old furnace system to producemagnesium chloride flakes

• A 500 kWth capacity updraft gasifier system was installed at PMW(Pioneer Magnesia Works), Kharagoda, in Rann of Kachchh

• Daily magnesium chloride flakes production: 25 tons• Fuelwood consumption reduced by more than 55%

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Plaster of Paris (PoP), Rajasthan

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Gasifier for green brick drying in KeralaImportance/relevance:• need to dry bricks before firing in kiln• need to dry in shade to avoid cracks• long drying periods 40-45 days• large inventory: need huge shade space• artificial drying required in cloudy weather• huge fuel consumption in bin method

(about 1000 kg for 2000 bricks in 2-3 days)• smoky operation: poor working conditions

Achievements• Reduction in fuel consumption (to 250 kg)• Reduction in drying time (to 24 hrs)• Improved working conditions (no smoke)

Traditional bin method

Updraft gasifier system withmultiple burner

Gasifier for CO2 making, Gujarat

Producergas

Carbon dioxide

Flue gas with outcarbon dioxide

Boiler

Carbon DioxideSeperator

Cum Regenerator

Gasifier Fluegas withCarbon Dioxide

for bottling

MEP (after CO Extraction)

MEP (with CO2 )

2

2

(100 kg/h)

Gasifier system for crumb/blockrubber drying units in Kerala

• India is fourth largest producer of natural rubber

after Thailand, Indonessia and Malasia

• A 100 kg/hr capacity gasifier installed to replace elctricity/diesel

used for drying crumb rubber in tunnel dryer

• About 30 litre diesel is saved per hour

Gasifier for institutional cooking at Gram Vikasresidential school hostel at Konkia in Orissa

Achievements:• Reduction in fuel consumption

to less than 100 kg/day• Improved working environment

No smoke• Takes same time without blower• Time saving with small 0.1 HP blower

(1 hr for breakfast, 2 hrs for lunch)

Background:• 300 student residential school• Firewood consumption:

300-400 kg/day(For breakfast, lunch & dinner)

• Smoky working conditions• Slow process

(2 hrs for breakfast, 3 hrs for lunch)

Gasifier cooking system at Radha Soami Satsang,Beas

Gas burner and flame

Gasifier-based cooking system to cook150 kg of dal (pulses)/600 kg of subzi (vegetable)Conventional cooking oven

Salient Features• Large-scale cooking application (of over300 kWth capacity)• Dal/sabzi cooked in each batch can serve 6,000 people• About 50% reduction of fuel consumption• Provides clean and smokeless working environment• One-time fuel feeding for the entire day cooking operation• Flexible heat input using gas control valves• Other Applications: Hotels/hostels/dhabas/hospitals/marriage/

community halls, religious places like temples and gurudwaras

Traditional crematorium

• Cremation, traditional burial practice of Hindus,

is major wood consuming activity in India

• Daily 20-30,000 bodies are cremated in Hindu tradition

• 400-600 kg fuel required for cremating body

• Estimated annual consumption 5 million tonnes

• Increasing pollution hazard as many unburnt bodies

are thrown into the rivers due to scarcity of fuelwood

• Dead bodies are placed in close chamber andexposed to high temperature above 1000 C

• Electric crematoriums, diesel/natural gas fired• Normally too costly technologies• Initial capital investment about Rs. 1.5-2.0 million• High operating costs

* about 100-150 kWh per cremation(on round the clock operation)

* about 25-30 liter diesel per cremation

Modern technologies• Recent solar crematorium (with electric back up)

under construction at Satya Sai Baba Trust at Valsad(concentrating collector dish alone costs Rs 1 million)

Gasifier based Crematoria (Goa)

**

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*

*

*****

*

**

*

**

*

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1

3

11

2 1

1

258

1 55

5

23

1

26154 4

TERI thermal gasifiers in India

1

*

1

1

**

*

*

*

*

*

*

**

Western India

Figu Engg

2 M

Paramount

Silk TexGreenergy

Vijay Engg

ChanderpurUrjex

Hi-Tech

Manufacturers of TERI gasifiers in India

Important lessons: Thermal Applications

1. Introduction of a gasifier is not just an addition, but an

integration (both technological and cultural) with the existing

traditional/conventional practice

e.g. in silk reeling and cardamom curing technological

integration was successful, but cultural/social integration was

not adequate.

Product Development Approach

Important lessons: Thermal Applications2. Recognition of “proud owners”in some categories

Use of shining “SS” in place of rust prone mild steel at slightly

higher costs.

3. Tread carefully/plan strategically where government

presence/control is predominant

e.g. Dept of Horticulture gave the order to an un-initriated/un-

trained manufacturer in Sikkim in order to achieve

“numbers”. Result: Breakage/cracking of high temperature

lining material in many installations

Important lessons: Thermal Applications4. Strategy for market promotion not yet very clear. Current efforts

through existing users, local service providers (LSPs) and

consultants, and through workshops/business meets.

5. Strong QA/QC (specially material selection, welding quality,

casting and curing of high temperature insulation) needs to be

enforced through third party inspection

6. User education/training is critical for ensuring

• Safety

• Use of properly sized/dried wood

7. Financing through FIs and effective utilization of existing

government incentives (e.g. accelerated depreciation) yet to

be channelized properly

8. Options for short term/long term linkages for sustainable

biomass supply need to be explored (e.g. possibility of

replacing wood with pellets of agro-residues)

Important lessons: Thermal Applications

TERI Power Gasifier Installations

100% PRODUCER GAS

Dhanwas, Haryana1989-1994Briquette7 kVA

Kanheiput, OrissaMay 2004-Charcoal10 kWe

Deodhara, OrissaOct 2004-Wood10 kWe

Jamera, ChhatisgarhMar 2005-Wood10 kWe

Bhaogarh, RajasthanMar 2006-Mustard stalk10kWe

Yamunanagar, Haryana2004-Wood100 kWe

TERI, GuwahatiNov 2005-Wood50 kWe

ThailandJun 2006-Coconut shell100 kWe

Sanjay Basti, UttaranchalSep 2004-Lantana50 kWe

TERI, Gual Pahari1994-2005Wood40 kWe

DUAL FUELLocationYearFuelCapacity

7 kWe mobile power plant at Dhanawas, HaryanaPower generation

Salient features:• All sub components assembled on trolley making

it an mobile source of power• Used for more than 5 years (1989-1994, about 2000 hrs) for

• community lighting in village• for converting local mustard stalk into briquettes

Water seal at bottom Plunger type fuel agitatorHelical fuel agitator

Development of 40 kW gasifier design

Final design of 40 kW gasifier

Final gas cooling-cleaning train configuration

0

500

1000

1500

2000

2500

3000

3500

0 50 100 150 200 250 300Time (Minute)

TT

PM

(mg/

Nm

3).

After CYL After VS

After PBF After SBF

Performancemonitoring

(Gradual reductionin TTPM)

40 kWe power plant at TERI’s Gual Pahari campus

Salient features:• Multi-fuel capability (can use woody, briquetted loose biomass)• Existing DG set can be coupled to run on dual fuel mode• One kg wood gives about 1 kWh electric power• Up to 80% diesel replacement achieved using turbocharger• Low operating cost (about Rs 2.5 against Rs 4.5 per kWh)• Low installation cost (about 15-20,000 per kW)• Suitable for decentralized power generation in remote areas

GasifierGravity dust settling chamber

Cyclone

Venturi scrubberPacked bed filter

Sand bed filter

Modified 50 kWe gasifier

Major modifications:• Preheated air supplied to gasifier to release volatiles• Air supply through two layers of air nozzles in firebox• Fuel charging door with water seal for quick fuel charging• Conveyer-bucket hoist mechanism for fuel loading

50 kWe Biomass gasifierDual Fuel System in Uttaranchal

Biomass Gasifier Dual fuel Engine Street Lighting

Location: Shanti Nagar Basti, Ranipokhri, DehradunMain feed stock : Lantana (Forest weed)

100 kWe (Dual Fuel) systemInstalled in Thailand

Development of100% Producer Gas Engine

Engine Parameters• Conversion of CI to SI engine• CR reduced from 17:1 to 14:1• Spark advance of 26 to 28 BTDC with distributor

Simple Speed control device developed as safety device

Simple Governor mechanism developedfor air+gas mixture

• Can take care of load fluctuations maintaining

• frequency (50±1) with load variations within minute

• frequency (50±0.1) with normal load variations

10 kWe system (TERI):System Specification

• Power output:10 kWe

• Fuel: Wood/Charcoal

• Gas cooling

– Water cooling (direct/indirect)

• Gas cleaning

Combination of cyclone, Venturi scrubber, gravel, fabric and

paper filters

• Engine: Kirloskar RV-3 (modified for operation on 100%

producer gas by TERI)

• Initial starting: Pedal, DG set, Battery/inverter

IndirectGas

cooler

Adsorptionon

charcoal bed

FoamFilter

Gasstoragesurge/buffertank

Cooled, Cleaned Gasto modified diesel enginefor 100% gas operation

AirBlower

Preheated air(150-200C)

Provision for possible future useDowndraftthroatlessGasifier

Grate

Heat exchangerfor air preheating

Evaporative water cooler(Desert cooler)

Gasifier cover with water seal

DustSettling

Chamber

Cyclone-2

HotGravel

BedFilter

Cyclone-1

FlaringPipe

10 kWe Charcoal system in village KanheiputSystem Configuration:• Dust Settling Chamber• Cyclones• Gravel Bed Filter• Indirect Gas Cooler• Foam Filter• Buffer Storage tank• Safety Paper Filters

Salient Features:Indirect Gas Cooler Minimizes• Waste Water Generation• Moisture carry overEasy to maintain in Rural areasLow maintenance cost• Uses low cost local materials

• Gravel• Foam, etc

100% gas engine system at Kanheiput, Orissa

Gasifier lower portion (Firebox, airblower, grate shaker, ash pit tank)

Gasifier top (fuel hopper and fuel chargingdoor with chain pulley system)

Pedal operated blower installedat Kanheiput in September 2004

DTU team inspecting system components

System has logged more than 2,500 hour till mid 2006

Condition of Paper Filter-2 after 200 hours of field operation

Close up of outer surface Close up of inner surface

Installation of governor at Kanheiput(In September 2004)

0

10

20

30

40

50

60

0 20 40 60 80 100

Tim e (Minutes)

Lo

ad(k

W),

Fre

qu

ency

(Hz)

,T

hro

ttle

op

enin

g(d

egre

e)

15041505150615071508150915101511151215131514

RP

M

Load kW e Hz Throttle opening Rpm

Frequency variations with varying loads

4949.249.449.649.8

5050.250.450.650.8

0 5 10 15 20 25 30 35 40 45 50

Tim e interva l in seconds

freq

uen

cy(H

z)

0

2

4

6

8

10

load

(kW

e)

Hz

kW e

Frequency variation without governorunder constant load

Frequency variations without governor

49.50

50.0050.5051.0051.5052.00

52.50

0 5 10 15

No. of readings

Freq

uenc

y(H

z)

3

3.1

3.2

3.3

3.4

load

(kW

e)

Frequency KW electircal

Frequency variation with governorunder varying loads

40

42

44

46

48

50

52

54

0 2 4 6 8 10 12 14

No. of readings

Freq

uenc

y(H

z)

012345678910

Load

(kW

e),E

xces

so

xyge

n%

inen

gine

exha

ust

Frequency (Hz)

Load (kWe)

Excess oxygen % in engine exhaust

Frequency variations with varying loads 3R1040

49

49.2

49.4

49.6

49.8

50

50.2

50.4

50.6

50.8

0 5 10 15 20 25 30 35 40 45 50

Time interval in seconds

frequ

ency

(Hz)

0

1234

56

78910

load

(kW

e)

Hz kWe


0

12

34

5

67

8

0 20 40 60 80 100

Time (Minutes)

Load

(kW

),Fr

eque

ncy

(Hz)

,Th

rottl

eop

enin

g(d

egre

e)50.05

50.1

50.15

50.2

50.25

Load kWe Hz


Two stage gasification concept of TERI

Two stage gasification concept of DTU

Tar reduction concept byprimary methods

Vill.Deodhara - a panaromic view

Street lighting

A well-lit household

Village electrification –Gasifier at Village Deodhara,Orissa

PLAN

ELEVATION

10 kWe gasifier systemat village Jamerra

Month Actual hours thesystem operated

Total no. of hours duringthe month @4 hours perday

November 05 79 124

December 05 109 120

January 06 73 124

February 06 83 112

March 06 86 124

April 06 73 120

May 06 120 124

623 856

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�Engine related issues : 12%

�Social issues (related to collection ) : 9%

�Distribution network related issues ` : 3%

�Fuel wood non availability due to excessive rains : 1%

�Operator un availability : 1%

Major reasons of non-availability

Characterization of wastewater

• Waste water was characterized for eight systems

– Capacity range: 10 kW to 100 kW

– Fuel varieties: mixed wood (local wood like Eucalyptus,

Acacia), Ipomea (local weed), Rice husk, charcoal

– Sources of water: ash pit, gas cooling system: venturi (I, II

as per system design)

– Type of systems: updraft and down draft system (dual fuel,

100% producer gas based system)

1.6-1.842-7098-7423.5-8.08.32-8.65

Venturi II

1.8-5.4141-170140-5413.9-4.610Venturi I

2-4304-65286-1251.4-2.2>10Ash Pit

Wood

1.2-840-10051-5408.4-263.38-3.96

Tar Pit

1.4 -1940-195052-6509-493.21-3.65

Coolingwater

4- 845-850121-6644-393.21-4.69

Ash Pit

Ricehusk

1.01.00.255.5-9.0Disposal standards

ISI

Alkalinity(g/l)

Chloride(mg/l)

Phenol(mg/l)

COD (g/l)pHSourceFuel

Characterization of Wastewater

Treatments studiedActivated charcoal

adsorption– Char made from

• Bagasse

• Coconut husk

• Gasifier Charcoal

• Rice husk

• Saw dust

– Type of treatments for activatedcharcoal preparation:• Untreated

• Steam activated

• Thermal activated

• Acid activated

• Acid+thermal activated

64

66

68

70

72

74

76

78

80

82

84

T-G

asifi

erch

arco

al

S-G

asifi

erch

arco

al

Gas

ifier

Cha

rcoa

l

T-ric

ehu

sk

A-r

ice

husk

S-r

ice

husk

A-g

asifi

erch

arco

al

Per

cent

phen

olre

duct

ion

• T : thermal activated• S: Steam activated• A: Acid activated

Microbial treatment of waste water

• Microbes were isolated from the effluent treatment system of HindustanOrganic Chemicals (HOC), Cochin

• Enriched and isolated microbes were identified as– Micrococcus– Pseudomonas– E.coli– Staphylococcus

• Phenol degradation performance

13.5632.8Staphylococcus

15.5842.2E.coli

12.5245.6Pseudomonas

15.048.8Micrococcus

Rate of degradation (mg/h)Phenol reduction (%)Microbial strains

Important Lessons:Gasifier Power Plants

• Major scope where biomass is produced ‘in-

situ’ e.g. rice mills

However, technology for rice husk gasification is

yet to mature. The current plants based on updraft

gasification and extensive cleaning of gas are

highly polluting

Important Lessons:Gasifier Power Plants (contd…)

• High degree of social mobilization needed forrunning rural power plants sustainably. Tariffcollection on a continued basis is a big challenge,which can probably be leveraged by livelihoodand income generation activities (Needssubstantial state support). The lure of freeelectricity from the grid is too big to handle


• The capital costs of establishing distributed

generation and micro-grids are about 50% higher

than centralized power at present and can be

brought down further. The economic costs of

providing electricity to remote users are also

comparable for both routes. Plant availability can

be made as high as desired through training of

local operators. Increasing the PLF, however,

needs sustained efforts.

• Control of engine is largely manual. Substantial

R&D needed for optimization of engine

performance, reduction of CO emissions and for

rugged speed control. Servicing of engines and

gasifier systems is a major cost item at present


• Future R&D needed for reducing tars in raw gas

substantially (e.g. through two-stage gasification)

for reducing costs both for engine maintenance

and for gas cleaning

• R&D needed for treating gas cleaning wastewater

and for providing value added products (e.g. low

cost membranes from biomass ash)


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biomass gasification: success stories and lessons … · gasifier for co 2 making, gujarat...

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