Gas producer Renewable energy source

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Introduction Gas Producer Basic Operation Cyclone Fuel Compartment Scrubber/Cooler Cooling Water Filters Vacuum Indicator Bio-mass Fuel Engine Conversions Operation & Function Life Span Detail Data Installations

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CARBO CONSULT & ENGINEERING (Pty) Ltd

P.O. Box 1397, Cramerview 2060 Johannesburg, South Africa

Tel:	+27 11 314 1354
Fax:	+27 11 314 1480
E-mail:	info@carboconsult.com
Web:	www.carboconsult.com

THE ENVIRONMENTALLY FRIENDLY WOOD GAS PRODUCER SYSTEM WITH TAR FREE CONTINUOUS GAS PRODUCTION FOR ELECTRIC POWER GENERATION AND / OR HEAT APPLICATIONS.

1. GAS PRODUCER DESCRIPTION

The System Johansson Gas Producer has been developed as an environmentally friendly downdraft wood gasification technology on the principle that all tar is cracked at high temperature with long gas residence time in the pre-heated refractory cast-cement hearth. It has been designed for varying load on demand as is necessary for continuous char surplus. The gas when leaving the gas producer is tar-free.

This is a fully developed, reliable and clean, over many years long-term tested source of renewable biomass energy for direct engine/generator or heat applications. It has been specially designed for use in developing countries, where communities have the will and government support to establish their own energy plantations in suitable areas with straight and fast growing clean trees while at the same time creating new employment and learning opportunities. If the plantations were large, they would contribute to reduce the green house effect with assimilation of the CO2 in the air through photosynthesis by the oxygen producing trees.

The whole integral Gas Producer System has also been designed for simplicity and safety, provided that the Operator’s and Safety Instructions are followed. Small plants can under Developing World conditions be operated by persons with only an experienced tractor driver’s skills, while larger plants will need to be operated under the guidance of an engineer or a qualified mechanic. Large capacity fuel compartments are provided to allow for extended time between re-fuelling, which is important when used as electricity power supply during late night time, low power output hours with isolated communities.

The gas producers are also suitable for use with forest- or sawmill waste converted to fuel of specified piece shape and size. High density briquetted sawdust, groundnut husks, sunflower shells and other Biomass materials have been successfully tested without producing any tar.

In warm sunny climates the logs, after being cut to suitable handling lengths, are normally stacked to dry for a few months before being converted into wood block fuel or coarse chunks. The sun drying is usually enough, but after-drying with engine radiator waste heat may sometimes be necessary.

For fuel drying in cold or rainy climates as well as with wet sawmill waste, exhaust gas fuel dryers can be used. Since no tar is produced, the clean gas producer system can, for use in Industrialised Countries, be adapted with semi or full automated function control and suitable modifications for mechanisation to the refuelling and ash removal systems.

The Fuel Compartment with its shape and volume in relation to the maximum gas production forms an integral part of the tar free gas producer system. To avoid fuel hang-up, the drying and carbonisation funnel have been determined to allow for free through-flow without obstruction. The average shrinkage of wood during drying and the necessary controlled speed of carbonisation at high temperature in relation to volume reduction and char demand has also been taken into account with the hearth design.

The whole gas producer system operates under vacuum. This makes the system safe against gas poisoning, particularly during re-fuelling with continuous non-stop working as long as the engine or in the case of heating applications, the gas suction fan is running. The preheated primary air makes the system respond instantaneously to any variations in the gas demand.

The tar free gas producer design is based on tar cracking formulas. The wood gas producer system is available in 5 different Standard Design Normal Sizes, from 120 Nm3/h to 850 Nm3/h gas production, (50 KVA to 400 KVA) or (180 Kwth/h to 1,300 kWth/h for heat application) respectively. There are also 5 Special Design Large Non-Standard Sizes from 1,100 Nm3/h to 2,400 Nm3/h gas production, but at this stage only design data is available.

The gas producers are provided with primary air nozzles, giving the correct pre-heated air velocity to allow for full air penetration through the coarse char in the combustion zone, even at low power. The primary air is pre-heated through a built-in heat exchanger, which conserves heat and increases the hearth temperature.

SJG Gas Producers have been long-term tested with trouble free performance under actual working conditions over many years.

2. TAR FREE WOOD GAS REFERENCE

The reference to "tar free" wood gas generation is based on the fact that no tar could be detected in the clean gas during the early CSIR tests with the original prototype carried out during 1984 and 1985. Later tests conducted by CRE with a 450 Nm3/h SJGas Producer in the UK during 1993-1995 also found no tar in the gas. From long-term continuous combined tar and dust tests carried out over many years, when the gas producers have powered generators with varying electric power output, the average total combined tar plus 5 micron dust collected on the safety filter has been about 6 mg/Nm3 clean gas.

3. WOOD GAS ANALYSIS

During 1983 and 1984 CSIR carried out various internal temperature measurements, gas analysis and gas producer performance tests with the first tar free S J G proto-type gas producer. The average gas composition from the gas analysis when converted to air free gas is as shown below. The effective heat values varied slightly, mainly as a result of variations in the wood fuel moisture content.

The average effective heat value of the air free gas varied between 5,900 kJ/Nm3 to 6,250 kJ/Nm3 while the volume of gas formed under low power conditions was 2,2 Nm3/kg wood block fuel. At full power the wood consumption increased due to duffing and carbon losses, while the volume of gas formed per kg wood decreased to about 2 Nm3/kg wood. The early CSIR practical working gas yield results were confirmed many years later during tests carried out with the larger, for continuous working designed, System Johansson Wood Gas Producer delivered to Eskom (Electricity Supply Commission of South Africa).

CRE also carried out gas analysis in the UK during 1995 on gas from a 450 Nm3/h System Johansson Gas Producer, when high density sawdust briquettes were used as fuel. These UK test results showed a higher gas heat value than what was recorded by CSIR with the first tests, when Eucalyptus Camaldulensis wood block fuel was used. No tar was detected with any of these tests.

Basic Operation ...