9.1 Biomass Production: 9.1.1 Direct Methods
9.1 Biomass Production: 9.1.1 Direct Methods
1 BIOMASS PRODUCTION
Sun is the primary source of all kinds of available raw energy resources including biomass.
The sunlight energy is transferred to biosphere by the photosynthesis process that occurs in
plants, algae, and some types of bacteria.
It is seen that in the process, water and carbon dioxide are converted into organic material.
The term biomass refers to those organic matters that are stored in plant and trees in the form
of carbohydrate (sugar). It is then transferred through food chains in humans, animals, and
other living creatures and their wastes.
The term biomass includes all plant life: trees, agricultural plants, bush, grass and algae, and
their residues after processing. Biomass may be obtained from forests woods, agricultural
lands, arid lands, and even waste lands. It may be obtained in a planned or unplanned manner.
The term is also generally understood to include animal and human waste.
Biomass has the advantage of controllability and availability when compared to many other
renewable energy options. There are a variety of ways of obtaining energy from biomass. These
may be broadly classified as direct methods and indirect methods.
Raw materials that can be used to produce biomass energy are available throughout the world
in the following forms:
Raw biomass has a low energy density based on their physical forms and moisture contents
and their direct use are burning them to produce heat for cooking. The twin problems of
traditional biomass use for cooking and heating are the energy inefficiency and excessive
pollution.
Inefficient way of direct cooking applications, inconvenient and inefficient methods of raw
biomass transportation and storage and high environmental pollution problems made them
unsuitable for efficient and effective use. This necessitated some kind of pre-processing and
conversion technology for enhancing the usefulness of biomass.
9.1.2 Indirect Methods
Biomass can also be used indirectly by converting it either into electricity and heat or into a
convenient usable fuel in solid, liquid, or gaseous form. The efficient conversion processes are
as follows:
An interesting approach for the large-scale planned use of wood is the ‘energy plantation’
approach. In this scheme, selected species of trees are planted and harvested over regular
intervals of time in a phased manner so that wood is continuously available for cooking or
allied purposes.
Energy plantations include, amongst others, pine, cottonwood, hybrid poplar, sweetgum, and
eucalyptus. Much of the emphasis has been on hardwood plantations due to their ability to
coppice, continued genetic improvement programs as well as the opportunity to combine fast
growth and wood. Some important trees grown in India for this purpose are eucalyptus, babool,
and casuarinas.
It has been suggested that electrical power be produced by the energy plantation approach,
the wood grown in this manner being used as a fuel for the boilers of a conventional power
plant. The technology of biomass-based electric power plants is well established in the USA
and Europe and there are over 500 such plants use wood, wood waste, and various types of
agricultural waste.
Biomass gasification is a process of partial combustion in which solid biomass usually in the
form of pieces of wood or agricultural residue is converted into a combustible gas mixture.
Gasification produces a synthesis gas with usable energy content is produced by gasification
in which biomass is heated with less oxygen than that needed for complete combustion.
As a result, a gaseous mixture of carbon monoxide (CO), carbon dioxide (CO2), methane
(CH4), hydrogen (H2), and nitrogen (N2) called producer gas is obtained.
Since any biomass material can undergo gasification, this process is much more attractive than
ethanol production or biogas where only selected biomass materials can produce the fuel.
1. Drying of fuels: It is the process of drying biomass before it is fed into gasifier.
2. Pyrolysis: It is a process of breaking down biomass into charcoal by applying heat to
bio-mass in the absence of oxygen.
3. Combustion: All the heat required for different processes of gasification are made
available from combustions.
4. Cracking: In this process, breaking down of large complex molecules (such as tar) takes
place when heated into lighter gases.
5. Reduction: Oxygen atoms are removed in this process from the combustion products
(hydrocarbon) molecules and returning them to combustible form again.
The producer gas is a mixture of carbon monoxide (CO), carbon dioxide (CO2), hydrogen
(H2), methane (CH4), and nitrogen from air.
The composition of producer gas is highly dependent upon the inputs to the gasifier and gasifier
design.
Table 9.1 lists the composition of gas produced from various sources. Nitrogen affects the
maximum dilution of gas and almost 50%–60% of gas is composed of non combustible
nitrogen.
On an average, 1 kg of biomass produces about 2.5 m3 of producer gas at S.T.P and consumes
about 1.5 m3 of air for combustion.
(9.2)
Example 9.1
One kilogram of wood produces 2.5 m3 of gas with average calorific value of 5.4 MJ/m3.
Average calorific value of wood (dry) is 19.8 MJ/kg. Calculate the average conversion
efficiency of wood gasifier.
Solution From Eq. (9.2), ηgs = (2.5 × 5.4 × 106) /(19.8 × 106 × 1) = 68.18%.
The complete combustion of biomass produces biomass gasses that generally contain
nitrogen, water vapour, carbon dioxide, and surplus of oxygen. However, in gasification (with
incomplete combustion), as shown in Figure 9.1, product gas contains gases such as carbon
mono oxide (CO), hydrogen (H2), and traces of methane and non-useful products such as tar
and dust. Thus, the key to gasifier design is to create conditions such that
Biomass gasifier may be considered as a chemical reactor in which biomass goes through
several complex physical and chemical processes and producer or syngas is produced and
recovered.
1. Fixed bed gasifier: In this gasifier, biomass fuels move either countercurrent or
concurrent to the flow of gasification medium (steam, air, or oxygen) as the fuel is
converted to fuel gas. They are relatively simple to operate and have reduced erosion.
Since there is an interaction of air or oxygen and biomass in the gasifier, they are
classified according to the way air or oxygen is introduced in it. There are three types
of gasifier as shown in Figure 9.2.
1. Downdraft gasifiers: In the downdraft gasifier, the air is passed from the layers
in the downdraft direction. Single throat gasifiers are mainly used for stationary
applications, whereas double throat gasifier is used for varying loads as well as
automotive purposes.
2. Updraft gasifiers: Updraft gasifier has air passing through the biomass from
bottom and the combustible gases come out from the top of the gasifier.
3. Cross draft gasifiers: It is a very simple gasifier and is highly suitable for small
outputs.
Four distinct processes take place in a gasifier when fuel makes its way to gasification:
1. Drying zone of fuel: In this zone, the moisture content of biomass is removed to obtain
the dry biomass. Some organic acids also come out during the drying process. These
acids give rise to corrosion of gasifiers.
2. Pyrolysis zone: In this zone, the tar and other volatiles are driven off. The products
depend upon temperature, pressure, residence time, and heat losses. However,
following general remarks can be made about them.
1. Up to the temperature of 200°C, only water is driven off.
2. Between 200°C and 280°C carbon dioxide, acetic acid, and water are given off.
3. The real pyrolysis, which takes place between 280°C and 500°C, produces large
quantities of tar and gases containing carbon dioxide. Besides light tars, some
methyl alcohol is also formed.
4. Between 500°C and 700°C, the gas production is small and contains hydrogen.
3. Combustion(oxidation) zone: In this zone, carbon from the fuel combust and forms
carbon dioxide with the oxygen in the air by the reaction:
4. Reduction zone: The hot gas passes through the reduction zone after the combustion
zone. As there is no free oxygen in this zone that causes inflammable carbon dioxide
gas to react with the carbon in the fuel and forms flammable carbon monoxide gas. This
reaction is endothermic (demands heat) and occurs at temperature exceeding about
1,000°C. Carbon monoxide is the most important flammable elements in the produced
gas obtained from the reduction reaction as
(9.3)
Another important endothermic reaction in the reduction zone is the water–gas shift reaction.
It is the reaction of water vapour and carbon to give carbon monoxide and hydrogen
(9.4)
Both gasses are flammable, and the heating value of the gas is increased. If there is still surplus
of water in the reduction zone, then carbon monoxide may react with water vapour and form
carbon dioxide and hydrogen. The reaction is
(9.5)
Equations (9.3) and (9.4) are main reduction reactions and being endothermic have the
capability of reducing gas temperature.
The conversion efficiency of a gasifier is defined as the ratio of the heat content in the
producer gas to the heat content in the biomass supplied and is usually around 75%.
The oldest and simplest type of gasifier is the counter current or updraft gasifier shown
schematically in Figure 9.3. The air intake is at the bottom and gas leaves at the top (the counter
current flow). The reactive agent is injected at the bottom of the reactor and ascends to the top,
while the fuel is introduced at the top and descends to the bottom. The combustion reactions
occur near the grate at the bottom that are followed by reduction reactions somewhat higher up
in the gasifier. In the upper part of the gasifier, heating and pyrolysis of the feedstock occur as
a result of heat transfer by forced convection and radiation from the lower zones. Gases, tar,
and other volatile compounds are dispersed at the top of the reactor, while ash is removed at
the bottom. The syngas typically contains high levels of tar, which must be removed or further
converted to syngas for use in applications other than direct heating.
Updraft gasifiers are widely used to gasify biomass resources and generally use steam as the
reactive agent, but slagging can be severe if high ash fuels are used. They are unsuitable for
use with fluffy, low-density fuels.
These gasifiers are best suited for applications where moderate amounts of dust in the fuel gas
are acceptable and a high flame temperature is required. Typical applications where the updraft
gasifiers have been successfully used are as follows:
1. Packaged boilers
2. Thermal fluid heaters
3. Aluminium melting/annealing furnaces
4. All kinds of fryer roaster
In this gasifiers, the primary gasification air is introduced at or above the oxidation zone in the
gasifier and the producer gas is removed at the bottom of the apparatus, so that fuel and gas
move in the same direction, as schematically shown in Figure 9.4. The biomass feed (such as
wood waste) and its gasification air both flow in the same downward direction through the
gasifiers’ fuel bed.
The biomass feed is admitted at the top similar to the updraft gasifier. As the feed progresses
down through the gasifier, it dries and its volatiles are pyrolysed. The char is directed into a
reduced-diameter cylindrical throat section at the bottom of the gasifier. Gasification air is
injected into the throat through openings in the throat wall. Due to the high temperatures
existing at the throat section, tars and oils could be cracked, which tend to form in producer
gas, particularly when the biomass is wetter than about 20% moisture content (wet basis). The
producer gas leaves at the bottom of the gasifier. The start-up time of about 5–10 min is
necessary to ignite and bring plant to working temperature with good gas quality is shorter than
updraft gas producer.
Downdraft gasifiers are widely used in the following applications:
Figure 9.5 is a schematic representation of cross-draft gasifier. Unlike downdraft and updraft
gasifiers, the ash bin, fire, and reduction zone in cross-draft gasifiers are separated.
Figure 9.5 Cross-draft gasifier
These design characteristics limit the type of fuel for operation to low ash fuels such as wood,
charcoal, and coke. The relatively high temperature in cross-draft gas producer has an obvious
effect on gas composition such as high carbon monoxide, and low hydrogen and methane
content when dry fuel like charcoal is used. Cross-draft gasifier operates well on dry air blast
and dry fuel.
The biomass is fed in at the top at regular intervals of time and is converted through a series
of processes into producer gas and ash, as it moves down slowly through various zones of the
gasifier.
Fluidized bed gasification has been successfully used to convert prepared wastes (i.e., wood
wastes, bark, agricultural wastes, and RDF (Refused Derived Fuel) into a clean fuel gas that
can be used to fire various types of industrial equipment
The fluidized bed gasifier is illustrated schematically in Figure 9.6. This gasifier is an
improved version of fixed bed gasifiers. The bed made of an inert material (such as sand, ash,
or char) initially and it is heated and the fuel is introduced when the temperature has reached
the appropriate level. The bed material transfers heat to the fuel and blows the reactive agent
through a distributor plate at a controlled rate. Fluidized bed gasifiers have no distinct reaction
zones (as in the case of fixed bed gasifiers) and drying, pyrolysis and gasification occur
simultaneously. The fuel particles are introduced at the bottom of the reactor, very quickly
mixed with the bed material and almost instantaneously heated up to the bed temperature. As
a result of this treatment, the fuel is pyrolysed very fast, resulting in a component mix with a
relatively large amount of gaseous materials. Further gasification and tar-conversion reactions
occur in the gas phase.
Figure 9.6 Fluidized bed gasifier
For biomass feeds which have high ash content and the ash has low melting point, fluidized
bed combustion seems to gasify them.
The fluidized bed gasification process offers several substantial benefits when compared to
simple burning processes and other forms of gasification.
9.10.1.1 Advantages
1. Reduced cost of boiler or dryer or kiln operation by using wood and/or bark wastes
rather than gas or oil.
2. Reduced cost for additional steaming capacity when compared to new wood and or
bark-fired boilers.
3. Reduced dependency on external fuel sources for propane, natural gas, and oil.
9.10.1.2 Benefits
1. High overall efficiency: High efficiency in the range of 70%–90% can be achieved.
2. Fuel flexibility: The fluidized bed gasifiers have fuel flexibility and operate
satisfactorily with highly variable feed materials. Ranging from coal, shredded wood
and bark to sawdust fines, or lump wood with particle sizes of less than 4–6 cm.
3. Highly reliable: The fluidized bed gasifier neither have moving grates nor other moving
parts in the high temperature regions of the bed and hence they are highly reliable.
4. Low purchase and installation costs: Air flow used in the gasifiers is comparatively
low, and hence size of gasifier is small and compact.
5. Flexible operations: Fuel gas product of fluidized bed gasifier is easily applied to a
variety of industrial processes. Thus, they provide flexible operations.
6. Low emissions: They are very low emission gasifiers and do not require exhaust clean
up devices.
The output of a biomass gasifier can be used for a variety of direct thermal applications such
as cooking, drying, heating water, and generating steam. It can also be used as a fuel for internal
combustion engines to obtain mechanical shaft power or electrical power.
If used as a fuel for internal combustion engines, it has to be cleaned first for complete
removal of particulate material and tar. A cleaning system consisting of cyclone, a scrubber,
and a filter is used for the purpose. If the engine is a spark-ignition engine, it can operate with
producer gas alone. The gas is sucked from the gasifier and cleaner unit by the engine suction
along with a proportionate amount of air. It is then compression-ignition engine, as it operates
in the ‘dual-fuel’ mode. Here, the engine sucks in a mixture that is compressed and a small
amount of diesel sprayed in. Combustion initiates with the diesel droplets and then spreads to
the mixture of the gaseous fuel and air. The phrase ‘dual-fuel’ implies that both diesel and
producer gas are simultaneously used.
India is one of the leading countries in the world in the field of biomass gasification. Biomass
gasifier systems are available in a wide range of capacities and standard facilities for testing
and evaluating gasifiers have been set up. For thermal applications, systems with outputs
ranging from 60,000 to 5 × 106 kJ/h are available, while for electrical power generation,
systems with outputs ranging from 3 to 500 kW are also available.
The largest biomass gasification system produces 5 × 106 kJ/h (1,450 kW) output in the
thermal mode and 500 kW in the electric power generation mode. It uses biomass in the form
of wood blocks (25 to 100 mm long and up to 70 mm in diameter) at the rate of 500 kg/h and
produces 1,250 m3/h of gas.
When compared to gaseous fuels such as producer gas or biogas, liquid fuels are somewhat
harder to obtain from biomass sources. One of the methods is the production of methanol from
wood or straw. The process involves the gasification of plant matter followed by chemical
synthesis. Another method is the conversion of certain food grains and crops such as sugarcane,
maize, cassava and tapioca by fermentation into ethanol. When blended with petrol, ethanol is
good alternate fuel for automotive engines.
Most of gasifier manufacturers claim that a gasifier is available and can gasify any biomass
feed. However, there is no such thing as a universal gasifier. A gasifier is in real sense very
much biomass feed specific and it is tailored accordingly.
Following biomass feed characteristics or parameters dictate the quality and classification
of gasifiers:
The higher the energy content and bulk density of fuel, the similar is the gasifier volume; as
for one biomass fuel charge, power can be obtained for longer time duration.
Moisture content is very trivial components of biomass fuels and it is determined by the type
of fuel, its origin, and treatment. It is desirable to use fuel with low moisture content to
minimize heat loss due to its evaporation.
Thus, in order to reduce the moisture content of fuel, some pre-treatment of fuel is required.
Generally, desirable moisture content for fuel should be less than 20%.
All gasifier fuels produce undesirable dust that can clog the internal combustion engine and
hence it has to be removed. The gasifier design should be such that it should not produce dust
beyond specified limits.
The higher the dust produced, more is the load put on filters necessitating their frequent
flushing and increased maintenance.
Tar is one of the most unpleasant constituents of the gas as it tends to deposit in the carburettor
and intake valves causing sticking and troublesome operations.
Thus, the major effort has been devoted to cleaning this tar by filters.
9.12.5 Ash and Slagging Characteristics
The mineral content in the fuel that remains in oxidized form after complete combustion is
usually called ash. The ash content of a fuel and the ash composition has a major impact on
trouble-free operation of gasifier. Ash basically interferes with the gasification process in two
ways:
1. It fuses together to form slag and this clinker stops or inhibits the downward flow of
biomass feed.
2. Even if it does not fuse together, it shelters the points in fuel where ignition is initiated,
and thus lowers the fuel’s reaction response.
Ash and tar removal are the two most important processes in gasification system for its smooth
running. However, slagging can be overcome by two types of operation of gasifier:
1. Low temperature operation that keeps the temperature well below the flow temperature
of the ash.
2. High temperature operation that keeps the temperature above the melting point of ash.
1. Sugarcane and corn, wheat, sugar beet, sweet sorghum, and cassava to produce
bioethanol.
2. Rapeseed, sunflower seeds, soybean, canola, peanuts, jatropha, coconut, and palm oil
for biodiesel production.
3. Wide range of cellulosic materials (such as grassy crops, woody plants, by-products
from the forestry and agricultural sector including wood residues, stems, and stalks and
municipal wastes constitute the so-called second generation of feedstock).
4. Wastes and residues constitute a large source of biomass. These include solid and liquid
municipal wastes, manure, lumber and pulp mill wastes, and forest and agricultural
residues.
1. Motive power: Gasifier products are used to provide shaft power to industrial and
agricultural equipment and machinery such as
1. Diesel engine operation on dual or 100% modes.
2. Water pumps
3. Tractors, harvesters, etc.
4. Running of high efficiency Stirling engines.
2. Direct heat applications: Gasifiers heat has direct heat applications such as
1. Drying of agricultural crop and food products such as large cardamom, ginger,
rubber, and tea at low temperature range of about 85°C–125°C.
2. Baking of tiles and potteries in the moderate temperature range of about 800°C–
900°C.
3. For melting metals and alloys in non-ferrous in the temperature range of 700°C–
1,000°C.
4. As boiler fuels provide steam or hot water for process industries such as silk
reeling, dyeing, turmeric boiling, cooking, jiggery making, etc.
3. Electrical power generation: Electric power generation from few kilowatts to hundreds
of kilowatts either for local consumption or for grid power is being installed based on
gasifier products. Small-scale electricity generation systems also provide an attractive
alternative to electric supply company.
4. Chemical production: Production of chemicals such as methanol and formic acid from
producer gas.
For efficient and effective use of gas for numerous applications, it should be cleaned of tar and
dust, free from moisture content and cooled. Therefore, cooling and cleaning of the gas is one
of the most important processes in the whole gasification system. The failure or the success of
producer gas units depends completely on their ability to provide a clean and cool gas to the
engines or for burners.
The temperature of gas coming out of generator is normally between 300°C and 500°C. The
energy density of gas can be increased to a large extent by cooling it. Most coolers are gas to
air heat exchangers where the cooling is done by free convection of air on the outside surface
of heat exchanger. Some heat exchangers provide partial scrubbing of gas for the removal of
moisture and tar contents. Thus, ideally, the gas going to an internal combustion engine should
be cooled to nearly ambient temperature and shall be free from tar and moisture contents.
Normally, there are three types of filters used for cleaning of gas, as shown in Figure 9.7,
which is schematically a downdraft gasification system with cleaning and cooling train.
1. Cyclone filters: They are designed according to the rate of gas production and its dust
content. They are useful for particle size of 5 μm and greater. Since 60%–65% of the
producer gas contains particles above 60 μm in size, the cyclone filter is an excellent
cleaning device.
2. Wet scrubber: Even after cyclone filtering, the gas still contains fine dust, particles, and
tar. It is further cleaned by passing through a wet scrubber where gas is washed by water
in counter current mode. The scrubber also acts like a cooler, from where the gas goes
to cloth or cork filter for final cleaning.
3. Cloth filters: It is a fine filter. Any condensation of water on it stops the gas flow
because of an increase in pressure drop across it. Thus, in quite a number of gasification
systems, the hot gases are passed through the cloth filter, and then only do they go to
the cooler. Since the gases are still above the dew point, no condensation takes place in
filter.
SUMMARY
• Biomass gasification offers the most attractive alternative energy system for
agricultural purpose
• Most preferred fuels for gasification have been charcoal and wood. However biomass
residues are the most appropriate fuels for on-farm systems and offer the greatest
challenge to researchers and gasification system manufacturers.
• Very limited experience has been gained in gasification of biomass residues.
• Most extensively used and researched systems have been based on downdraft
gasification. However it appears that for fuels with high ash content fluidized bed
combustion may offer a solution. At present no reliable and economically feasible
systems exist.
• Biggest challenge in gasification systems lies in developing reliable and economically
cheap cooling and cleaning trains.
• Maximum usage of producer gas has been in driving internal combustion engine, both
for agricultural as well as for automotive uses. However, direct heat applications like
grain drying is very attractive for agricultural systems.
• A spark ignition engine running on producer gas on an average produces 0.55–0.75
kWh of energy from 1 kg of biomass.
• Compression ignition (diesel) engines cannot run completely on producer gas. Thus to
produce 1 kWh of energy they consume 1 kg of biomass and 0.07 l of diesel.
Consequently, they effect 80%–85% diesel saving.
• Future applications like methanol production using producer gas in fuel cell are under
investigation.
REVIEW QUESTIONS