Small Modular Biomass Gasification

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Small Modular Biomass Gasification

• Northeast Sustainable Energy Association
• Building Energy 07
• Seaport World Trade Center
• Boston, MA
• March 15, 2007

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Mount Wachusett Community CollegeCOMBINED HEAT
POWER PROJECT
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Biomax 50

• 50 kWe combined heat and power
• Thermal energy for heat
• Thermal energy for absorption chiller
• Electricity 8.1 liter GM turbocharged stationary
  engine with genset
• 24/6 operation
• No additional staffing
• transparent
• Seeking funding for other prime movers
• 1.5 tons/day green chips consumption

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Wood Chip Storage
Fine Filter
Heat Exchanger
Wood Chip Conveyor
Wood Chip Sorter
50 kW Genset
Feeder
Gasifier
Wood Chip Dryer
Feeder
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System Overview

• Fuel Conditioning
• Gasification
• Gas Cooling
• Gas Cleaning
• Power Generation

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System Components

• 10 components
• Messersmith Feeder
• Sorting Screen
• Dryer
• Fuel Feeder
• Gasifier
• Heat Exchanger
• Filter
• Engine/Generator
• Flare
• Control System

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Fresh Fuel Feeder

• Hapman Feeder
• 480VAC 3phase
• Requires fuel less than
• 2 x 1 x 1/2
• Fuel must be below 15 moisture content

Fuel to Gasifier
Surge Bin
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Gasifier

• 5 zones
• Fresh Feed
• Final Drying
• Flaming Pyrolysis
• Char Oxidation
• CO2 Heat
• Char Reduction
• CO H

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Heat Exchanger

• Shell and Tube
• Producer Gas through the tubes
• 16 tubes move independently of each other
• Cooling air is circulated around the shell

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Heat Exchanger (cont.)

• Heat Exchanger Operation
• Preheat
• Duct Heaters
• Gas Cooling
• Blower/Filter
• 800C to 110C
• Clean Out Ports
• Gasifier side
• Heat Exchanger Side

Motor Controller Backplane
120vac Breaker box
Gas Cooling Blower
Control Buttons
Pre-heater
Clean out port
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Filter

• Self Cleaning Bag Filter
• 5 cell filter
• Automatic char and ash removal system
• Safety filter downstream
• Rupture disks

Filter Cells
Safety Filters
Char Receiving Drum
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Filter (cont.)

• Filter Operation
• Preheat
• Strip Heaters
• Enclosure Fan
• Thermostatically controlled
• Char Augers
• Vertical and horizontal
• Char Receiving Drum

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Engine/Generator

• Commercial Gillette Engine/Generator Set
• GM V-8, 8.1 Liter, Vortec Engine
• WEG 60kW Generator

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Engine/Generator (cont.)

• Modified Engine
• In-line gas blower
• Automatic Engine Starting
• Control system controls the A/F ratio with the
  use of an O2 sensor
• Generator
• Can run in stand alone or utility parallel
  configuration
• 50kW Max continuous power

Wood Chips
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Flare

• Used to burn excess producer gas
• Located on building roof
• Hot surface igniter
• Thermocouple
• Flare Failure
• Dangerous CO gases
• Clear to Blue flame

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Control System

• Programmable Automation Controller (PAC)
• Compact Field Point
• 1 control module and a variety of I/O modules
• Can be connected to the internet or a LAN
• All incoming data is recorded and stored
• Automatic control and monitoring system
• Automated alarms, responses, and shutdowns

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Control System (cont.)

• Sensors
• Thermocouples
• Pressure Transducers
• Air Leak O2 Sensor
• Venturi Flow Meter
• Gasifier Feed Level Sensor
• Feed Gate Open and Closed limit switch
• Char Receiving bin Level Sensor
• Motor Controllers

Thermocouple
Pressure Transducer
Motor Controller
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Health and Safety

• High Temperature Hazards
• Particulates
• Electrical
• CO
• Explosion Hazards

High Voltage
Poison Gas
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Operating the BioMax 50 System

• Embedded Control Code
• 45 seconds boot-up cycle
• Pre-heat
• Char Bed Ignition
• Fresh Fuel Feeding
• Normal Operation
• Controlled Shutdown
• Emergency Shutdown

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Operating the BioMax 50 System(Computer
Interface)
XXXXX

• Connecting a computer to the control system
• LAN connection
• Direct Computer connection
• Opening the control program in a web browser

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Operating the BioMax 50 System(Computer
Interface cont.)

• Outputs Page
• Automatic/Manual Control
• Outputs Page
• Contains all set-points and control parameters

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Operating the BioMax 50 System(Computer
Interface cont.)

• Alarms Page
• Operator Alerts
• Yellow Alarms
• Red Alarms
• Operator Alert/Yellow Alarm/Red Alarm Page
• Individual alert/alarm on/off
• Individual alert/alarm message

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Operating the BioMax 50 System(Computer
Interface cont.)

• Data File Page
• Data File Save Location
• Hot Restart Button
• Engine Power Reading
• Logs Page
• Operator Notes
• Pre-Run Checklist Page
• Check off each task before starting a run

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Operating the BioMax 50 System( Initial Set and
Starting the System)

• Initial Set-Up
• Personal CO Monitors
• Check List
• Check all fuses and breakers
• Check all motors and electrical devices for
  secure wirings
• Check all mechanical connections (ex. Hose
  clamps, sanitary clamps)
• Engine fluid levels
• Char level in gasifier
• Engine and flare exhaust
• Cycle Control System Power
• Connecting a computer
• Password

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Operating the BioMax 50 System( Initial Set and
Starting the System)

• Starting the System
• Press the Start button
• Manually open the feed gate
• Verify gas flow through the system
• Verify Gas Cooling Blower Operation
• Verify pre-heaters are working
• Pre-heat
• System will run in preheat mode for approx
  30-50min
• Gasifier Ignition
• Filter Out Temp gt 40C

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Operating the BioMax 50 System(Normal Operation)

• Normal Operating Mode
• Fresh Fuel Feeding Gasifier temperature gt 800C
• Engine Start 10 minutes after gasifier fresh
  fuel feeding
• Excess gas to flare
• Operator Responsibilities
• Maintain fresh fuel in feed hopper
• Respond to system alerts and alarms

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Operating the BioMax 50 System(Controlled
Shutdown)

• Shutting the System Down
• Controlled Shutdown more desirable than an
  Emergency Shutdown
• Controlled Shutdown will stop feeder and shutdown
  the engine
• System will operate on the flare only
• Can be initiated by a user or by a Yellow Alarm
• If an operator is present during a controlled
  shutdown
• Operator can initiate and emergency shutdown once
  all fuel turns from black to a glowing orange
  color

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Operating the BioMax 50 System(Emergency
Shutdown)

• Emergency Shutdown
• Kills power to all electrical devices
• Shuts the feed gate
• Emergencies
• Gas Cooling Blower Failure
• Engine and Roots blower failure
• System clogged

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Operating the BioMax 50 System(Retrieving System
Data)

• Connect a computer to the control system
• FTP Protocol Internet Explorer
• Spreadsheet program

XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX
XXXXXXXXXXXXX
XXXXXXXXXX
Data Files
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Maintaining the BioMax 50 System(Overview)

• Maintenance
• Required for safe and efficient operation
• Every time the system is shutdown because of a
  controlled or emergency shutdown a maintenance
  task must be completed.
• Dangers associated with maintenance tasks
• Heat/burn hazards
• CO hazards
• Particulate hazards

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Maintaining the BioMax 50 System(Purge Procedure)

• Before opening any part of the BioMax 50 system
  for any reason the system must be PURGED!!!!
• Purging the system will
• Eliminate dangerous CO gases
• Prevent explosion hazards
• Can not purge the system until
• System has been at rest for 12 hours
• Gasifier temperatures are all lt 200C
• Stop the purge cycle immediately if Gasifier
  temperatures start to rise.

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Maintaining the BioMax 50 System(Heat Exchanger
Maintenance)

• Reasons to service the Heat Exchanger
• Excessively High Pressure Drop
• Poor gas cooling performance
• Remove gasifier side clean out port cover
• Remove heat exchanger out flange
• Use a vacuum and cleaning rods
• When re-assembling the heat exchanger flanges
  inspect the integrity of each gasket.

Clean out port
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Maintaining the BioMax 50 System(Filter
Maintenance)

• Reason to service the Filter or safety filter
• Excessively High Pressure Drop

Dirty Filter Bag
Clean Filter Bag
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Rob RizzoMount Wachusett Community
CollegeGardner, MA978-630-9137RRizzo_at_mwcc.mass.
edu