300 KG/HR OPEN TOP DOWN DRAFT

BIOMASS GASIFIER

OPERATION & MAINTENANCE MANUAL

 TABLE OF CONTENTS
PREFACE 3
I PROCESS DESCRIPTION & APPLICATIONS.................................................................5
I A INTRODUCTION.......................................................................................................5
I B PRINCIPLE OF GASIFICATION...................................................................................5
I C APPLICATIONS........................................................................................................6
II SYSTEM CONFIGURATION & OPERATION..................................................................8
II A THE CLIENT..........................................................................................................8
II B SYSTEM OPERATION.............................................................................................8
II C SYSTEM CONFIGURATION......................................................................................9
II D GASIFIER............................................................................................................12
II E WASH WATER COOLING SYSTEM........................................................................13
II F FILTERING SYSTEM..............................................................................................14
II G GAS PIPING........................................................................................................15
II H BLOWER.............................................................................................................16
II I FLARE BURNER...................................................................................................16
II J ASH DISPOSAL SYSTEM.......................................................................................16
II K WATER TREATMENT SYSTEM..............................................................................17
II L CONTROLS..........................................................................................................17
II M SAFETY FEATURES.............................................................................................18
III OPERATION & MAINTENANCE..............................................................................21
III A LOADING THE SYSTEM.......................................................................................21
III B FEEDSTOCK REQUIREMENT................................................................................21
III C START-UP PROCEDURE......................................................................................22
III D OPERATIONAL SEQUENCE FOR MANUAL MODE...................................................22
III E MONITORING THE SYSTEM.................................................................................23
III F OPERATION & MAINTENANCE OF WATER TREATMENT PLANT..............................25
III G SHUTDOWN SEQUENCE.....................................................................................30
APPENDIX I - LEAK TEST AFTER ASSEMBLY
31
APPENDIX II – DO’S AND DON’T’S
33
DO’S............................................................................................................................33
DON’TS.......................................................................................................................34
APPENDIX III - UNLOADING THE REACTOR 35
APPENDIX IV - GASIFIER SPECIFICATIONS
36
APPENDIX V - MAINTENANCE SCHEDULE
37
APPENDIX VI - REPORTING FORMATS 38

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 PREFACE

This manual provides information on the construction, operation and maintenance of

a 300-kg/hr bio-residue gasifier system for thermal application. Part I of the manual
provides detailed information about the concepts, construction and working of the
gasifier system. Part II provides information pertaining to operation and maintenance
of the gasifier. The maintenance protocol for bought-out accessories follows the
recommendations of the respective manufacturer.

3 OPERATIONS & MAINTENANCE MANUAL

 PART I

PROCESS DESCRIPTION & APPLICATIONS

4 OPERATIONS & MAINTENANCE MANUAL

 I PROCESS DESCRIPTION & APPLICATIONS

I.A INTRODUCTION
Since prehistoric times, biomass has been the single major source for meeting the
energy needs of mankind. Only after the late 18 th Century, have fossil fuels such as
coal and petroleum displaced wood as an energy source. Even now, biomass is still
widely used to meet the domestic and community cooking needs and for limited
industrial use in most developing countries. Wood and other bio-residues, besides
being used in solid form, can be gainfully converted into gaseous form through
gasification route. Gasification technology thus affords more precise control over
energy levels and can cater to various thermal and electrical energy needs. The
following sections provide information on the present state of the art of biomass
gasification technology and its applications.

I.B PRINCIPLE OF GASIFICATION

Biomass* is a natural substance, which accumulates solar energy as chemical
energy by the process of photosynthesis in the presence of sunlight. Biomass chiefly
contains cellulose, hemi-cellulose and lignin, having an average composition of
C6H10O5, with slight variations. Theoretically, the ratio of air-to-fuel required for the
complete combustion of biomass, defined as stoichiometric combustion, is 6:1 to
6.5:1 (1 kg of wood requiring 6 – 6.5 kg of air), with the end products being CO 2 and
H2O. In gasification, biomass is subjected to partial pyrolysis under sub-
stoichiometric conditions with air-to-fuel ratio being maintained at 1.5:1 to 1.8:1 (1 kg
of biomass requiring 1.5 - 1.8 kg of air). The resultant mixture of gases, thus
generated during the gasification process, called collectively as producer gas, is
combustible. This process is made possible in a device called gasifier. A typical
gasifier system consists of a reactor, which receives air and solid fuel and converts
them into gas, followed by a cooling and cleaning train wherein cooling and cleaning
of the gas takes place. The clean combustible gas is available for power generation
in diesel-generator set or for heat in burners.

In the reactor, biomass feedstock, after undergoing drying and de-volatilisation in the
upper zones, leaves behind char. The volatiles undergo oxidation in the combustion
zone, with air being partially supplied by the surrounding nozzles, and the remaining
being drawn from the open top.
The product gases further get reduced in the bed of charcoal and yield a
combustible gas called producer gas, having calorific value of 4.5- 5.0 MJ/m 3 (1000
– 1200 kcal/ m3).
Producer gas has the following average chemical composition.

CO: 20 + 2%;

5 OPERATIONS & MAINTENANCE MANUAL

CH4 : 3 + 1%,
H2 : 20 + 2%,
CO2: 12 + 1%
Rest: N2.

* Biomass is any botanical derivative with bulk density greater than 250 kg/m 3 and
ash content less than 2 - 3%. Typical examples are various species of wood such
as Casuarina, Acacia, Eucalyptus, Prosopsis Juliflora, coconut shell, cotton
stalks, mulberry twigs and weeds such as Ipomoea. Powdery and loose
bioresidue such as rice husk, De-Oiled Bran, saw dust etc. should be compacted
to achieve higher density. Such agro-residue generally tends to have higher ash
content of 6% to 20%.

I.C APPLICATIONS
Producer gas, obtained by the process of gasification, can be employed in thermal
application or for mechanical/electrical power generation. Like any other gaseous
fuel, producer gas affords much better control over power levels when compared to
solid fuel. This also paves the way for more efficient and cleaner operation. Producer
gas can be conveniently used in a number of applications as detailed below

I.C.1 THERMAL
Thermal energy of the order of 4.5 to 5.0 MJ is released, by burning 1 m 3 of producer
gas in the burner. Flame temperatures as high as 1500 K can be obtained by
optimal pre-mixing of air with gas. For thermal applications, gasifiers are a good
option as a gas generator and can be retrofitted with existing devices. Producer gas
can thus replace fossil fuels in a wide range of devices. A few of the devices which
could be retrofitted with gasifiers are furnaces for melting non-ferrous metals and for
heat treatment, tea dryers, ceramic kilns, boilers for process steam and thermic fluid
heaters.

I.C.2 POWER GENERATION

A diesel engine can be operated on dual fuel mode using producer gas. Diesel
substitution of the order of 80 to 85% can be obtained at nominal loads. The
mechanical energy thus derived can be used either for energising a water pump set
for irrigational purpose or for coupling with an alternator for electrical power
generation. Alternatively, a spark ignition fitted engine can be operated with producer
gas on 100% gas mode for the same applications

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 PART II

SYSTEM CONFIGURATION & OPERATION

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 II SYSTEM CONFIGURATION & OPERATION

II.A THE CLIENT

The client currently uses LDO for operating its 8 Normalising & tempering furnaces
and proposes to replace the use of LDO with producer gas from the gasifier system.

II.B SYSTEM OPERATION

The 300-kg/hr Gasifier system is an open top downdraft system, where both gas
and feedstock move downward as the reaction proceeds. The air required for
gasification reaction is partially drawn from the top, and partially through secondary
air nozzles surrounding the combustion zone and one central air nozzle directed to
the reactor core. The required suction for this process is provided by a set of
blowers. Biomass feedstock, after drying and pyrolysing in the upper zone of the
reactor, undergoes volatile combustion leaving char by the time it reaches the
oxidation zone.

In the oxidation zone, the volatiles undergo oxidation with the release of CO 2 and
H2O. These product gases further undergo reduction in the presence of hot bed of
charcoal and yield a combustible gas mixture. The hot gases exiting the reactor
bottom pass through a series of Cooling and Cleaning Equipment. The first is an
Indirect Cooler, where the product gas loses some of its sensible heat to a
circulating jacket. It then passes through a dry Cyclone, where most of the
particulate matter entrained in the gas stream is removed by centrifugal action. The
gas then passes through a counter current direct cooler, where the gas is thoroughly
scrubbed by a water spray. In this process the gas is cleaned and cooled to near
ambient temperature. The gas is further led through a water scrubber, a wet cyclone,
a DCC and a blower.

The Piping & Instrumentation Drawing of the gasifier system is shown in Fig. 1
(Please refer to Part II for specifications).

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 FIGURE 1 – P & I DIAGRAM OF 300 KG/HR GASIFIER

II.C SYSTEM CONFIGURATION

The Gasifier System consists of the following sub-systems :

Sr. No. Sub-systems Quantit Eqpt. No.

y
A. BIOMASS CONVEYING SYSTEM
A.1. Intake hopper 1
A.2. Vibratory Feeder 1
A.3. Bucket Elevator 1
A.4. Retractable Chute 1
B. GASIFIER
B.1. Retractable Top cover 1
B.2. Reactor 1
B.3. Central Air Nozzle 1
B.4. Central Air Nozzle Cooling pumps 2
B.5. Central Air Nozzle Cooling piping 1
B.6. Central Air Nozzle Cooling Tower 1
B.7. Secondary Air Nozzles 6

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C. WASH WATER COOLING SYSTEM
C.1. Indirect Cooler 1
C.2. Direct Cooler 1
C.3. Main Cooling Water Circulation pumps 2
C.4. Main Cooling Water Circulation piping 1
C.5. Main Cooling Water Sump 1
C.6. Wash Water Circulation pumps 2
C.7. Wash Water Circulation piping 1
C.8. Wash Water Sump 1
C.9. Wash Water Cooling Tower 1
D. FILTERING SYSTEM
D.1. Dry Cyclone 1
D.2. Water Scrubber 1
D.3. Mist Separator / Moisture Trap 3
D.4. Wet Cyclone 1
D.5. DCC 1
E. GAS PIPING
E.1. Main header 8” 72 M
E.2. Flare Burner Line 4” 4M
E.3. Burner Lines 3” 30 M
E.4. Burner Lines 2” 40 M
F. BLOWER 2
G. FLARE BURNER 1
H. ASH DISPOSAL SYSTEM
H.1. Screw conveyor with geared motor 1
H.2. Ash dump with water seal 1
H.3. Hydropack for screw conveyor 1
I. WATER TREATMENT SYSTEM
I.1. Pressure Sand Filter 1
I.2. Activated Carbon bed 1
I.3. Treatment Plant Circulation pumps 2
I.4. Treatment Plant Circulation piping 1
I.5. Treatment Water Sump 1
I.6. Centrifuge 16” 1
J. CONTROLS
J.1. PLC based control panel 1
J.2. Operation control desk 1
J.3. Air compressor 1
K. SAFETY FEATURES
K.1. Oxygen Analyser 1
K.2. Pressure sensors 2
K.3. Manometers 6
K.4. Temperature sensors 2
K.5. Flame Trap 1

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K.6. Control valves
K.6.1. Pneumatic (PV2 on Main Gas Header) 8” 1
K.6.2. Pneumatic (PV1 on Flare Burner) 4” 1
K.6.3. Pneumatic (PV3 on Flame Trap for draining during start- 3
up, PV4 on Flame Trap for filling during shutdown, PV5
common on Air Nozzles for filling during start-up)
2”
K.6.4. Solenoid (SV1 common on Air Nozzles for draining 2
during start-up, SV2 on Ash Dump) 1”

II.C.1 BIOMASS CONVEYING SYSTEM

The conveying system is designed to feed the reactor at a rate suitable for
continuous operation of the gasifier at variable power levels. The maximum designed
rate of conveying is 500 kg/hr. The conveying system has four elements, which are:

II.C.1.1 INTAKE HOPPER

An intake hopper is provided at the bottom of the Bucket Elevator, which has
sufficient capacity to store about 1 hour’s biomass consumption at full capacity. As
the level of biomass in the hopper reduces during operation, it is periodically refilled
using trolleys.

II.C.1.2 VIBRATORY FEEDER

A vibratory feeder is provided at the bottom of the hopper. This is meant to separate
fines, mud, sand etc. from the biomass prior to feeding into the gasifier reactor. It
also facilitates smoother flow of the feedstock. The feeder is designed for intermittent
operation, whenever the conveyor is activated. This feeds the biomass into the
buckets for further transportation.

II.C.1.3 BUCKET ELEVATOR

The Bucket Elevator consists of a series of suitably sized buckets, which are
arranged on an endless chain between gear wheels. The entire assembly is
enclosed in a metal shroud to prevent damage and accidents. The bucket elevator
transports the biomass fed into the bottom buckets to the top of the reactor. Its
operation is controlled from the Control Desk as well as from the PLC control panel.

II.C.1.4 RETRACTABLE CHUTE

The Bucket elevator is provided at the top with a retractable Chute through which the
biomass falls into the gasifier reactor. The outlet of the Chute, which is in extended
position whenever the gasifier is in operation, opens directly into the Gasifier top, to
facilitate biomass loading. The Chute is provided with a pneumatic retraction system.
In ‘Close’ position during gasifier shutdown, the Chute is always retracted. In ‘Open’
position during start-up and operation, it is always extended..

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II.D GASIFIER
The gasifier consists of the following elements, which are

II.D.1 RETRACTABLE TOP COVER

The Gasifier is provided with a top cover, which is fitted with a pneumatic retraction
system. In ‘Close’ position during gasifier shutdown, the Top Cover is always
extended and seated in a water seal. In ‘Open’ position during start-up and
operation, it is always retracted. Pressure controller and oxygen analyser on the gas
stream control its retraction and extension.

II.D.2 REACTOR
The reactor is a cylindrical vessel with outer walls made of mild steel, which is
internally insulated with cold face insulation bricks, hot faced insulation bricks and
ceramic tiles composed largely of alumina.

II.D.3 CENTRAL AIR NOZZLE

To allow for uniform air availability across the reaction bed, the gasifier is provided
with a central air nozzle. This nozzle made of Stainless Steel and provided with a
cooling water jacket extends from the outside wall of the reactor to the reactor core
and is always kept open during operation and always kept closed during shutdowns.
This is achieved by providing the inlet to the Central Air nozzle with a drain cup,
which fills with water during shutdown procedure and from which water is drained
during start-up procedure. During start-up procedure, a common 1” solenoid valve
(SV1) drains the drain cup of the Central Air Nozzle. During shutdown procedure, a
common 2” Pneumatic Control Valve (PV5) allows water from the Water tank to flow
by gravity to the drain cups of the Central Air Nozzle and the Secondary Air Nozzles.
These valves are activated by signals from the pressure controller and the oxygen
analyser in the gas stream during emergency shutdowns.

II.D.4 CENTRAL AIR NOZZLE COOLING PUMPS

The Central Air Nozzle is kept cooled during the gasifier operation and a minimum of
four hours after shutdown, by circulating water in an outside jacket that covers a
good length of the nozzle from the reactor periphery inwards.

II.D.5 CENTRAL AIR NOZZLE COOLING PIPING

The Central Air Nozzle Cooling piping conveys water from a water tank to and from
the jacket of the Central Air Nozzle.

II.D.6 CENTRAL AIR NOZZLE COOLING TOWER

A cooling tower is provided for reducing the temperature of the water, which picks up
heat while circulating in the jacket of the Central Air nozzle. This extends the life of
the Nozzle besides affording continuous operation of the gasifier.

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II.D.7 SECONDARY AIR NOZZLES
There are 6 air nozzles, made of high alumina, arranged radially around the
combustion zone. These nozzles extend from the outside wall of the reactor into the
reactor and are always kept open during operation and always kept closed during
shutdowns. This is achieved by providing the inlet to the Secondary Air Nozzles with
drain cups, which fill with water during shutdown procedure and from which water is
drained during start-up procedure. During start-up procedure, a common 1” solenoid
valve (SV1) drains the drain cup of the Secondary Air Nozzles. During shutdown
procedure, a common 2” Pneumatic Control Valve (PV5) allows water from the
Water tank to flow by gravity to the drain cups of the Central Air Nozzle and the
Secondary Air Nozzles. These valves are activated by signals from the pressure
controller and the oxygen analyser in the gas stream during emergency shutdowns.

II.E WASH WATER COOLING SYSTEM

The sub-assembly consists of the following components

II.E.1 INDIRECT COOLER

The gas exiting at the reactor bottom passes through a duct provided parallel to the
reactor. This duct has a water cooled outer jacket which helps in reducing the
sensible heat of the hot gas. The gas then passes into the Dry Cyclone.

II.E.2 DIRECT COOLER

This is located downstream of the Dry Cyclone. This is a counter current type Direct
Cooler, with top flange having a water spray arrangement. The spray is developed
from an impinging jet, which mixes with the gas and cools the gas to near ambient
temperature and in the process removes dust and tar entrained in the gas. The
spray nozzles are so located as to allow for each of them to be individually opened
and cleaned during maintenance. The rate of water flow is set around 150 - 200 lpm.
The Direct Cooler is connected to the Water Scrubber.

II.E.3 MAIN COOLING WATER CIRCULATION PUMPS

A water pump is deployed for the purpose of pumping water into the Direct Cooler
and the Water Scrubber from the Main Cooling Water Sump. The flow rate is
maintained at 450 lpm during the operation of the gasifier and a pre-determined
period of time thereafter. The water from the cooler dump overflows into the
scrubber water seal from where it is further discharged to the Wash Water sump.
Another pump is provided as stand-by in the event of breakdown of the first pump.

II.E.4 MAIN COOLING WATER CIRCULATION PIPING

The Main Cooling Water piping consists of supply from the Main Cooling Water
Sump to the top of the Direct Cooler, and thence to the Wash Water Sump.

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II.E.5 MAIN COOLING WATER SUMP
The Main Cooling Water Sump collects the water that returns from the Cooling
Tower and provides storage for Water for cooling the Direct Cooler and the
Scrubber. It also provides storage for Water for on-line parallel processing of Wash
Water in the Treatment Plant.

II.E.6 WASH WATER CIRCULATION PUMPS

The Wash Water Circulation pump performs the function of circulating the Cooling
Water collected in the Wash Water Sump to the top of the Cooling Tower so as to
reduce its temperature to near ambient. Another pump is provided as stand-by in the
event of breakdown of the first pump.

II.E.7 WASH WATER CIRCULATION PIPING

The Wash Water Circulating piping consists of supply from the Wash Water Sump to
the top of the Cooling Tower, and thence to the Main Cooling Water Sump.

II.E.8 WASH WATER SUMP

The Wash Water Sump collects the water that returns from the Direct Cooler and the
Water Scrubber.

II.E.9 WASH WATER COOLING TOWER

The Wash Water Cooling Tower removes the sensible heat of the Wash Water and
helps in maintaining the temperature of the Cooling Water at near ambient. This is
connected to the Main Cooling Water Sump.

II.F FILTERING SYSTEM

The gas filtering train consists of a Cyclone, Water Scrubber and Mist Separator.

II.F.1 DRY CYCLONE

This is a tangential flow cyclone, where the gas from the Indirect Cooler enters
tangentially at the top separating the entrained particulates by centrifugal action. The
exit of the Cyclone is connected to the Direct Cooler. There is provision at the
Cyclone bottom to collect particulate matter. This needs to be discharged/removed
on daily basis as a part of the daily preventive maintenance schedule for the system.

II.F.2 WATER SCRUBBER

The Water Scrubber cleans the gas further by intimately mixing it with Cooling Water
from the Main Cooling Water Sump. There is a cooler dump provided at the bottom,
which collects the water and helps in draining out collected particulates. The rate of
water flow is set around 120 lpm. The Water Scrubber is provided with a manometer
and a temperature sensor. The Scrubber is connected to the Mist Separator.

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II.F.3 MIST SEPARATOR / MOISTURE TRAP
The gas after getting filtered in the Water Scrubber passes through a mist separator,
where the entrained moisture is separated from the gas stream. This is connected to
the Wet Cyclone.

II.F.4 WET CYCLONE

The gas gets filtered in the Wet Cyclone by centrifugal action and the entrained
particulates and moisture get collected at the bottom, which are then drained to the
sump. The rigid HDPE piping which connects the cyclone bottom and the sump
should always be immersed in water and should not be exposed to atmosphere to
prevent air entrainment in the gas stream.

II.F.5 DCC
The gas from the Wet Cyclone is then sent through a DCC, where the gas is given a
thorough diesel wash. This process substantially reduces the particulate and tar
content in the gas and facilitates trouble free operation of the Client’s furnace control
devices such as ratiotrol further downstream.

II.G GAS PIPING

The cooled and cleaned gas is finally piped to the furnace area

II.G.1 MAIN HEADER - 8”

The producer gas from the system flows into two streams, one to the flare burner
through a 4” Pneumatic Control Valve (PV1), and another going to the furnaces
through an 8” Pneumatic Control Valve (PV2), both of which are activated by signals
from the pressure controller and oxygen analyser. The Main Gas Header pipe is 8” in
diameter and transports the cleaned gas from the Gasifier System to the Furnace
area. This Main Header is provided with a Flame Trap at the Gasifier end.

II.G.2 FLARE BURNER LINE - 4”

The Flare burner is a gas burner and is provided with a 4” Pneumatic Control Valve
(PV1). At the time of start-up, the Flare burner is used to flare the producer gas
during stabilisation of its quality. Once the flame stabilises, the valve is closed and
the gas is diverted to the Main Burners. The Pneumatic Control valve is also
activated by signals from the pressure controller and oxygen analyser during
shutdown. It is then used to flare off the residual producer gas in the system.

II.G.3 BURNER LINES 3” & 2”

The gas from the Main Gas Header is piped to each of the Tempering & Hardening
Furnaces via a 3” line, which is further reduced to 2” at the Ratiotrol, which controls
the air-fuel mixture at the burner end.

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II.H BLOWER
Blowers having a rating of 900 m 3/Hr at 1500 mm of WG provide the required suction
for induction of air for gasifier operation. The rate at which producer gas is
consumed by the furnaces is controlled by ratiotrol, provided on each furnace. Each
furnace is provided with a gas line and an airline provided with air blower. A
thermocouple provides signal to the temperature controller, which operates the
servomotor, thus controlling the air intake. Once the set temperature and time
duration programmed by the temperature controller are achieved, the servomotor
cuts off air supply. The ratiotrol has a feedback loop from the air intake at the
servomotor and accordingly reduces the intake of producer gas from the blower
outlet.

II.I FLARE BURNER

This is provided to inspect the initial quality of the combustible gas and also for
flaring the residual gas in the system during shutdown.

II.J ASH DISPOSAL SYSTEM

The ash/charcoal generated by gasification of biomass collects at the bottom of the
reactor and is periodically drawn off for disposal/sale. The Ash Disposal System
consists of

II.J.1 SCREW CONVEYOR WITH GEARED MOTOR

The reactor bottom is provided with a screw conveyor. The screw conveyor is
provided with a water jacket for cooling the hot ash/char as it gets deposited. The
screw conveyor is fitted with a low rpm geared motor, which is periodically energized
to remove ash/char by timer (typically 1½ min per hour of gasifier operation). The
screw conveyor is automatically energised by input signal from the pressure
controller provided on the Indirect Cooler.

II.J.2 ASH DUMP WITH WATER SEAL

The ash/char from the Screw Conveyor is deposited in an Ash Dump, the outlet of
which is always immersed in a water seal. The Ash Dump is provided with a solenoid
valve (SV2), which operates only at the time of extraction. The Valve injects water
under pressure into the Ash Dump outlet so as to prevent ash build-up in the outlet
and also to cool the hot ash. The wet ash/char is periodically removed from the Ash
dump with the help of ladles, dried and disposed of / sold.

II.J.3 HYDROPACK FOR SCREW CONVEYOR

A hydropack is provided for raising and lowering the Screw Conveyor during
maintenance. The Screw Conveyor is lowered on to rails grouted to the floor to guide
it during removal and refitting process.

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II.K WATER TREATMENT SYSTEM
An off-line Water Treatment Plant continually treats the Wash Water in the Main
Cooling Water Sump to remove particulates/tar. The rate of flow is maintained at
about 90 lpm. The Treatment Scheme is as follows

II.K.1 PRESSURE SAND FILTER

The Wash Water is initially forced through a Pressure Sand Filter at a pressure of 2
kg/cm2. This removes most of the suspended particulates in the water. The water is
then led to the Activated Carbon Bed. The Pressure Sand Filter is backwashed with
fresh water once every 4 hours and the backwash water is filtered in a 16”
centrifuge.

II.K.2 ACTIVATED CARBON BED

The water from the Pressure Sand Filter is forced in a counter current against gravity
through an Activated Carbon Bed. Here most of the dissolved organics, odours and
colour are removed. The Activated Carbon bed is backwashed with fresh water once
every 4 hours and the backwash water is filtered in a 16” centrifuge.

II.K.3 TREATMENT PLANT CIRCULATION PUMPS

These pumps, one on-line and the other stand-by, are used for circulating clean
water for periodic backwashing of the Pressure Sand Filter and Activated Carbon
Bed. Their rate of flow is maintained at about 90 lpm.

II.K.4 TREATMENT PLANT CIRCULATION PIPING

This piping of HDPE is used to connect the Treatment Water pumps to the source of
fresh water and tot eh Pressure Sand Filter and the Activated Carbon Bed.

II.K.5 TREATMENT WATER SUMP

The Treatment water sump accumulates the backwash water for further processing
with the centrifuge.

II.K.6 CENTRIFUGE
Backwash water from the Water Treatment Plant is periodically passed through 16”
high-speed centrifuge to separate the dregs and particulates from the water, which is
then recycled. The dregs being mainly carbon can be disposed of as fuel after sun
drying.

II.L CONTROLS
The gasifier System is provided with an advanced Control system consisting of a
PLC based Control Panel and an Operation Control desk with manual override
capabilities.

17 OPERATIONS & MAINTENANCE MANUAL

II.L.1 PLC BASED CONTROL PANEL
The electrical motors and instrumentation are energized through the control panel.
The control panel houses a PLC, which is used for automatic operation of the
system. A pressure controller mounted on the Indirect Cooler and the oxygen
analyser monitor the pressure and oxygen concentration resp.. Whenever the above
parameters exceed acceptable limits, signals from the sensors activate the PLC
panel to initiate shutdown procedures. Timers are also provided to activate the
Screw Extractor at pre-determined intervals and for operating the various pumps
during and after the start-up and shutdown procedures.

II.L.2 OPERATION CONTROL DESK

There is also provision for manual override of the PLC based Control Panel through
a control desk provided near the reactor. All operators are trained to operate the
gasifier system for a period of 1 month from the date of start-up on a manual mode
and then only is the PLC Panel energised.

II.L.3 AIR COMPRESSOR

An air compressor of suitable capacity is provided to initiate the start-up and
shutdown procedures through the medium of Pneumatic control valves.

II.M SAFETY FEATURES

The following safety features have been incorporated in the Gasifier system to
ensure reliable, safe and foolproof manner.

II.M.1 OXYGEN ANALYSER

As the gasifier system is under suction the possibility of gas leaking out into the
ambient from most of the system elements is totally ruled out. However, there is
possibility of air leaking into the system thus diluting the gas. This could lead to back
travel of flame in the event of start-up, i.e., at the time of lighting or torching the gas
in the flare. To avoid such an eventuality, an oxygen analyser is provided at the
blower exit to monitor the oxygen level in the gas. In a normal satisfactory gasifier
operation, the oxygen level in the gas will be of order of less than 1.0%. In the event
of any external leak into the system, the analyser senses excess oxygen content and
initiates a trip signal to the PLC as also an alarm prompting the operator to take
corrective action. The PLC then initiates flooding of the drain cups of Central &
Secondary Air Nozzles and the flame trap in such an eventuality.

II.M.2 FLAME TRAP

Another element named flame trap is provided at the entry of the gas Main Header
upstream of Main Furnace Burners to prevent any back flare into the rest of the
system elements. The flame trap has a dedicated water reservoir with a 2”
Pneumatic Control Valve (PV3) for draining during start-up and another 2”
Pneumatic Control Valve (PV4) for flooding during shutdown. In case the oxygen

18 OPERATIONS & MAINTENANCE MANUAL

level in the gas reaches unacceptable levels, the flame trap will be automatically
flooded with water thus cutting off any back flare.

II.M.3 PRESSURE SENSORS

A pressure controller is provided at the Indirect Cooler inlet to monitor the pressure
on the gas stream. It provides electrical signal inputs to PLC panel in the event of
pressure exceeding preset levels for initiating emergency shutdown procedure.
Manometers are provided for monitoring pressure drop at the following five locations:
Indirect Cooler Inlet, Scrubber Inlet, Cooler Dump, DCC Inlet, DCC Outlet, Blower
Outlet.

II.M.4 TEMPERATURE SENSORS

Two temperature sensors are provided to monitor the temperature at different points
on the gas stream. The first is provided on the Indirect Cooler and the second on the
Water Scrubber.

II.M.5 CONTROL VALVES

The PLC controls the start-up and shutdown procedures with Pneumatic Valves.

II.M.5.1 PNEUMATIC CONTROL VALVE 8”

An 8” Pneumatic Control Valve (PV2) is provided at the gasifier end of the 8” Main
Gas Header.

II.M.5.2 PNEUMATIC CONTROL VALVE 4”

A 4” Pneumatic Control Valve (PV1) is provided at Flare Burner.

II.M.5.3 PNEUMATIC 2”
Two 2” Pneumatic Control Valves (PV3, PV4) are provided at the flame trap.

II.M.5.4 PNEUMATIC 1”
One common 2” Pneumatic Control Valve (PV5) is provided for flooding of drain
cups of the Air Nozzles.

II.M.5.5 SOLENOID 1”
Two 1” solenoid valves (SV1, SV2) are provided. The first is common for draining of
air nozzles and the second is for flooding of Ash Dump with water during ash
extraction as indicated earlier.

19 OPERATIONS & MAINTENANCE MANUAL

 PART III

OPERATION

&

MAINTENANCE

20 OPERATIONS & MAINTENANCE MANUAL

 III OPERATION & MAINTENANCE

III.A LOADING THE SYSTEM

Installation of the gasifier system should be followed by a leakage test (refer
Appendix 1). After the system successfully passes the leakage test, fuel should be
loaded into the reactor.

III.A.1 LOADING OF CHARCOAL

After ensuring that the ash extraction system is held properly bolted to the reactor
base, the reactor is loaded with dry charcoal, preferably till the top or at least 0.5 m
above the central air nozzle level. Initially large sized charcoal pieces measuring 100
x 100 x 75 mm are to be loaded, followed by even smaller ones up to 20 x 20 x 40
mm. Ensure that no extraneous material such as stones, sand. mud etc. is
loaded along with charcoal. Exercise extra caution during initial loading of charcoal
into the reactor. This is necessary because dropping charcoal from such a large
height would break it into pieces. The way for doing this as follows

1. Fill large sized pieces in small bags (3-5 kg holding capacity) and lower it by
means of a rope into the reactor from reactor top (use two ropes, one tied to the
top edge and the other to the bottom edge of the bag).

2. Release the charcoal slowly from the bag.

3. Repeat the above procedure several times until a bed/layer is formed across the
reactor.

4. Subsequently, the charcoal could be loaded by emptying large bags directly from
the reactor top.

5. Avoid using conveyor for loading charcoal, as it will be broken into pieces.

III.B FEEDSTOCK REQUIREMENT

The biomass that can be used in the reactor as the feed stock are various ranging
from woody biomass whose density is above 200 - 250 kg/m 3 and ash content less
than 2% to briquetted agro residue with less than 10% ash content. The feedstock
should have a mixture of sizes with large part being about 75 X 120 X 120 mm, and
having a maximum moisture content of 12-15% (Ensure that biomass is non-
termite ridden and contains no extraneous materials such as mud, clay, sand
etc). The first start of the gasifier requires the reactor to be loaded with dry charcoal.
However, the subsequent runs do not require fresh loading of charcoal, as it gets
generated on a continuous basis inside the reactor during gasification.

21 OPERATIONS & MAINTENANCE MANUAL

III.C START-UP PROCEDURE
The gasifier has been facilitated for automatic operation with preset logic in a PLC.
Manual operation is also possible through a control desk of the control panel. The
following chart shows the sequence of operations in auto and manual mode.

III.C.1 PROCEDURE TO START-UP GASIFIER

I.A.1.1.1 COMMON STEPS

1 Switch ON the panel Mains and check R, Y, B supply.
2 Switch ON the compressor main fuse switch.
3 Switch ON all motor feeders’ incoming fuse switch.
4 Switch ON all control MCB’S MCB-1 to MCB – 8.
5 Ensure emergency switch is released in the panel door.
6 Set control key system ON, Ready to start the system.
7 Select the Auto/manual mode selector switch, select to manual mode. This will
energise the auxiliary contactor K1toK7. In Auto mode this will not energise.
8 Ensure water in the water tank and all mechanical systems are at safe levels.

III.D OPERATIONAL SEQUENCE FOR MANUAL MODE

1 Switch ON the shut down drain water and Flame trap solenoid selector switch.
This will close the valve by energising K15 and K18 contactor through manual
selected contactor K5.
2 Press main water pump PB ON. This will start the pump by energising power
contactor C6 through manual selected contactor K2 and over load contactor
K28.
3 Press Wash water pump PB ON. This will start the pump by energising power
contactor C7 through manual selected contactor K2 and over load contactor
K29.

22 OPERATIONS & MAINTENANCE MANUAL

4 Press Fan motor PB ON. This will start the cooling motor fan by energising
power contactor C8 through manual selected contactor K3 and over load
contactor K30.
5 Switch ON the Nozzle pump selector switch. This will start the nozzle pump by
energising power contactor C9 and C10 (Fan motor) through manual selected
contactor K7 and over load contactor K31 and K32.
6 Switch ON the Top cover selector switch. This will open the top cover by
energising K11 contactor through manual selected contactor K4.
7 Switch ON the conveyor chute selector switch. This will bring chute to forward
direction by energising K12 contactor through manual selected contactor K4.
8 Switch ON the start up drain water – 1& 2 - selector switch. This will open the
valve by energising K13&k14 contactor through manual selected contactor K4.
9 Switch ON the start up valve selector switch. This will open the valve by
energising K10 contactor through manual selected contactor K3.
10 Press Blower – 1 PB ON. This will energise power contactor C1 through manual
selected contactor K1 and over load contactor K23.
After the flame is stabilised in the pilot burner mode, change over to main
burner.
11 Press Blower –2 PB ON. This will energise power contactor C2 through manual
selected contactor K1 and over load contactor K24.
12 Switch on the water trap selector switch to on this will open the valve by
energising K17 contactor through manual selected contactor K5.
Switch off the start up valve selector switch to off this will close the valve by de-
energising K10 contactor through manual selected contactor K3.

13 Switch on the main burner valve selector switch to on this will open the valve by
energising K9contactor through main selected contactor K3.

III.E MONITORING THE SYSTEM

The normal and proper working of the gasifier is ensured by visual inspection of the
air nozzles, which need to have a red-hot combustion zone in and around the

23 OPERATIONS & MAINTENANCE MANUAL

nozzles. Continuous flow of feed in the reactor is a good sign of normal gasification
process resulting in generation of good quality gas.

III.E.1 PARAMETERS FOR NORMAL OPERATIONS

1 Ensure that biomass is reasonably sized so as to have a bulk density of about
500 kg/m3 and that the moisture content is less than 10%
2 Maintain the correct level of diesel in the diesel sump as marked and also
correct level of water in the cooler dump tank.
3 Care should be taken to maintain the following while the gasifier is running to
near full capacity
3.a Pressure drop across the reactor is 220mm to 250mm of WG.
3.b Pressure drop across the water scrubber is at least (min) 50mm of WG.
3.c Pressure drop across diesel scrubber is 120mm to 140mm of WG.
3.d Cooling water pressure at the entry points into direct cooler and water
scrubber is 2 kg/cm2.
3.e Cooling water flow rate through direct cooler and scrubber is 120 lpm each.
3.f Diesel flow rate through DCC is at 100 lpm.
3.g Oxygen level in the Oxygen Monitor is < 1 %
4 Set duration of ash/char extraction during running of the gasifier to maintain a
pressure drop of about 220mm of water gauge across the reactor and also to
extract about 6 to 7% of biomass charge. This is approximately 1½ to 2 minutes
of extraction for every 100 kg of biomass loaded per hour.

III.E.2 MALFUNCTIONING AND TROUBLE SHOOTING

1 There could be air leakage into the gasifier, resulting in dilution of producer gas.
This leakage could be occurring at any location in the gasification system such
as flange joints, water seals etc. or in the gas line to the furnaces. This can be
detected with O2 analyser. This calls for immediate action to identify leakage
points to arrest it. A complete leak test is recommended before restarting the
gasifier
2 There could be blockage in the reactor or in the cooling or cleaning section,
causing resistance to the gas flow. To determine this, the pressure drops across

24 OPERATIONS & MAINTENANCE MANUAL

 various sub-systems have to be checked. Cleaning of various components at
specified intervals as indicated in appendix VIII would prevent immediate
recurrence of such blockage.
3 The level of particulates and dissolved organics in the cooling water going up
beyond acceptable limits during continuous operation of the gasifier should be
regularly monitored. This will directly affect the cleaning and scrubbing process,
which in turn will result in bad quality of gas being sent to furnaces. All the back
wash water, wash water and water from wash water sump is cleaned by
centrifuging continuously with a 16” centrifuge. Should the quality of water
deteriorate over time, it is advisable to replace at least 50% of the total water in
the cooling system, once in every 30days.
4 Irregular and non-uniform material movement implies that there are large air
gaps in the reactor caused by fuel bridging affecting the normal gasification
process. Use a lever or thin rod and stir the feed in the reactor from top till the
voids or gaps are removed.
5 There is every possibility of scales forming inside the cooling water jacket of
central air nozzle, during continuous operation. These scales prevent proper
flow of demineralised water around the jacket, thereby causing rupture of jacket
material. This will lead to spalding or water spraying onto the reactor hotbed
which is totally objectionable. It is advised that the Central Air Nozzle is removed
at regular intervals for inspection and repair of any damages, prior to
replacement in the reactor.

III.F OPERATION & MAINTENANCE OF WATER TREATMENT PLANT

III.F.1 THE PLANT
The water treatment plant consists of a pressure sand filter, an activated carbon
filter, a proportional dosing equipment and inter connecting pipes

III.F.1.1 PRESSURE SAND FILTER

The pressure sand filter consists of a mild steel pressure vessel fitted with control
valves and connecting piping.

25 OPERATIONS & MAINTENANCE MANUAL

The raw water is distributed by means of an inlet bell mouth pointing in an upward
direction inside the vessel.

The bottom water collector is of header and lateral type. The header lateral collecting
system consists of a mild steel header pipe with socket connections at the bottom
into which threaded PVC laterals are screwed. Each lateral has a number of holes
along its length through which the water can pass.

The vessel is painted inside with a special bituminous paint for corrosion resistance.
In the case of carbon filters used for de-chlorination, epoxy coating is generally
employed.

The filter media sand is supported on layers of inert under-bed material (pebbles and
gravel of various sizes). An air release pipe is provided for releasing the air from the
unit. Pressure gauges are provided on the inlet and outlet to ascertain the pressure
loss across the filters.

III.F.1.2 ACTIVATED CARBON FILTER

The activated carbon filter consists of a mild steel pressure vessel fitted with control
valves and connecting piping.

The raw water is distributed by means of an inlet bell mouth pointing in an upward
direction inside the vessel.

The bottom water collector is of header and lateral type. The header lateral collecting
system consists of a mild steel header pipe with socket connections at the bottom
into which threaded PVC laterals are screwed. Each lateral has a number of holes
along its length through which water can pass.

The vessel is painted inside with epoxy paint.

The filter media activated carbon is supported on layers of inert under-bed material
(pebbles and gravel of various sizes.) An air release pipe is provided for releasing
the air from the unit. Pressure gauges are provided on the inlet and outlet to
ascertain the pressure loss across the filters.

III.F.1.3 PROPORTIONAL DOSING EQUIPMENT

Proportional dosing equipment is compact, portable and self-priming. Dosing
arrangement is separate from chemical storage and hence solution tank size can be
chosen at will. Preparation and dilution of chemical solution can be done in the same
tank.

The chemical uptake is directly volumetrically proportional to the water flow.

Chemical dosing starts only with the water flow increasing when the flow increases

26 OPERATIONS & MAINTENANCE MANUAL

and decreasing when the flow decreases. This ensures that only the required
quantity (ppm) of chemical is dosed.

A micrometer type internal cylinder can be rotated through 10 turns to set the precise
dosing rate even when the pump is in use.

III.F.2 TECHNICAL SPECIFICATIONS & DATA

III.F.2.1 PRESSURE SAND FILTER

III.F.2.1.1 TECHNICAL SPECIFICATIONS

ONE Vertical, welded mild steel pressure vessel, complete with dished ends and
internally painted with anti-corrosive bituminous paint and externally with two coats
of primer.

ONE Set of internals for the above, comprising of raw water distributor and filter
water collecting system

ONE Set of frontal pipe work of mild steel, complete with vent piping and valves
Valves type : CI diaphragm flanged ends
Size : 40 NB
Air vent valve : 20NB

ONE Initial charge of filter media comprising of graded washed sieved gravel and
filtering sand

ONE Pressure gauge / sample valve

III.F.2.1.2 TECHNICAL DATA

No. offered ONE
Diameter mm 600
Height on straight mm 2000
Operating flow M3/hr 5.0
Back wash flow M3/hr 5.0
Back wash time Minutes 10-15 (for 8-10 hrs of operation)
Operating pressure Kg/cm2 3.5 / 2.0 (max/min)

III.F.2.2 ACTIVATED CARBON FILTER

III.F.2.2.1 TECHNICAL SPECFICATIONS

ONE Vertical, welded mild steel pressure vessel, complete with dish ends and
internally painted with anti-corrosive bituminous paint and externally with two coats
of primer.

27 OPERATIONS & MAINTENANCE MANUAL

ONE Set of internals for the above, comprising of raw water distributor and filter
water collecting system

ONE Set of frontal pipe work of mild steel, complete witH bend piping and valves
Valves type : CI diaphragm flanged ends
Size : 40 NB
Backwash inlet : 25NB
Air vent valve : 20NB

ONE Initial charge of filter media comprising of graded, washed, sieved gravel and
activated carbon

ONE Pressure gauge / sample valve

III.F.2.2.2 TECHNICAL DATA

No. offered ONE
Diameter mm 600
Height on straight mm 2000
Operating flow M3/hr 5.0
Back wash flow M3/hr 5.0
Back wash time Minutes 10-15 (for 8-10 hrs of operation)
Operating pressure Kg/cm2 3.5 / 2.0 (max/min)

III.F.2.3 PROPORTIONAL DOSING EQUIPMENT

III.F.2.3.1 TECHNICAL SPECIFICATIONS

Minimum dosing flow 1 Lt/hr
Maximum dosing flow 30 Lt/hr
Minimum actuation pressure 0.3 Kg/cm2
Maximum working pressure 5.0 Kg/cm2
Pressure loss at max. flow 1.2 Kg/cm2
Maximum operating temperature 50 Deg C
Inlet / Outlet connections ¾” BSPM
Dosing externally adjustable 0.5 to 2 %.

III.F.3 GUIDELINES FOR OPERATION

1. During normal operation the inlet and outlet valves are kept open. The flow
regulation should be done with the outlet valve.

2. Filter cleaning should be done whenever the pressure drop across the filter
exceeds the normal operating pressure drop by 0.35 kg/cm2 in the case of
sand filters.

The procedure for back wash cleaning is as follows:

28 OPERATIONS & MAINTENANCE MANUAL

 3. Close the inlet and outlet valves.

4. Open the wash outlet valve. Slowly open the wash inlet valve taking care to
see that filter media is not carried along with the water.

5. Continue until the wash water is clear. Then close the wash outlet valve and
open the air release valve.

6. When all the air is removed close the wash inlet and air release valve.

7. Open the inlet and drain valves. When the water becomes clear close the
drain valve and open the outlet valve. Set the flow at the desired value by
controlling the outlet valve.

8. The wash water flow is specified on the technical data sheet. It is essential
that it is not exceeded; otherwise filter media would be lost to the drain. Too
low a flow would mean incomplete cleaning of the bed.

III.F.4 MAINTENANCE
The routine maintenance of the PLANT should include the following:
1. VALVES
At periodic intervals (say once a month) open the valves and check seating and
gate. Attend to gland packing, replace if necessary, do routine lubrication of the
spindle.
2. EXTENDED BACKWASH
Once in a week extend the backwash operation to at least 45 minutes to keep the
bed clean.

3. ANNUAL SERVICING
Once in a year, check the condition of the paint inside the unit. If any signs of
corrosion are noticed, remove the media, clean the surface and apply 2 coats of
anticorrosive bituminous paint for sand filters and epoxy paint for activated
carbon filter.
4. STERLISATION OF CARBON FILTERS
a. During the initial starting up of the plant it is necessary to sterilise the sand
and carbon filters one after other (wherever provided). Operate the treatment
plant until approximately correct treatment is obtained. With all valves on
filters closed, proceed as follows:

29 OPERATIONS & MAINTENANCE MANUAL

 b. Open the wash outlet and air release valves on the sand filter, and the
suction valve on the pump and start the pump.
c. Gradually open the sand filter wash inlet valve until water discharges from the
waste pipe, then close the wash outlet valve. Close the air release valve
when water discharges from it, and then close the wash inlet valve.
d. Open the sand filter inlet and outlet valves. Open the carbon filter wash outlet
and air release valves.
e. Gradually open the carbon filter wash inlet valve and control the upward flow
of water to the indicating strip on the orifice board (if provided). If any
particles of carbon are carried over to drain, slightly close the wash inlet
valve. This procedure allows chlorinated water to pass downwards through
the sand and upwards through the carbon. The flow should be continued for
several hours.
f. Close the wash outlet, air release and wash inlet valves on the carbon filter
and open the inlet valve. Open drain valve.

g. Allow water to run downwards through the carbon to drain until the effluent is
free from chlorine. The treated water can then pass to service provide that
the other chemical tests are satisfactory.

III.G SHUTDOWN SEQUENCE

1 Press Blower –1 PB OFF. This will de-energise power contactor C1.
2 Switch OFF the water trap selector switch. This will close the valve by de-
energising K17 contactor.
3 Switch OFF the main burner valve selector switch. This will close the valve
by de-energising K9 contactor.
4 Switch ON the start up valve selector switch. This will open the valve by
energising K10 contactor.
5 Press Blower –2 PB OFF. This will de-energise power contactor C2.
6 Switch OFF the start up drain water –1&2- selector switch. This will close the
valve by de-energising K13&k14 contactor.
7 Switch OFF the shut down drain water solenoid selector switch. This will open
the valve by de-energising K15 contactor.

30 OPERATIONS & MAINTENANCE MANUAL

8 Switch OFF the conveyor chute selector switch to off. This will push the chute
backward by de-energising K12 contactor.
9 Switch off the Top cover selector switch to off this will close the top cover by de-
energising K11 contactor.
10 After ten minutes, switch OFF the start up valve selector switch. This will close
the valve by de-energising K10 contactor.
Note: All the motors Overload Relays are connected to the auxiliary contactors K23
to K33. If O/ L trips corresponding relay will energise and it will open
normally closed contact, which is inter locked with the power Contactor.

APPENDIX I - LEAK TEST AFTER ASSEMBLY

Procedure 1 : To be conducted when reactor is not hot.

1. Open the tubing at the exit of the blower.

2. Close the top cover and all air nozzles.
3. Pressurise the entire section with the help of a blower.
4. Apply soap water to all the joints. If any leakage exists, a bubble is formed at
that point. Mend all such leakages by appropriate tightening.

Procedure 2:

1) Connect the gasifier to the blower on flare mode (without lighting in the flare).

31 OPERATIONS & MAINTENANCE MANUAL

2) Light a wick. Blow off the flame (to generate smoke), and then hold the
extinguished wick at all possible points which are suspected to have leakages like
the flanged joints and pipe joints. In case there is leak, then there will be a tendency
for the smoke to be sucked or drawn inwards.

3) Mend all such leakages found and repeat the leakage test.

32 OPERATIONS & MAINTENANCE MANUAL

 Appendix II – DO’s AND DON’T’s

DO’S
Ensure that

1 The charcoal/biomass does not have any extraneous material such as stones,
metal, mud etc.

2 Adequate water level is maintained in all the water seals.

3 Water is being sprayed continuously in the cooler prior to and during the run.

4 Coolant water temperature does not exceed + 5C above ambient during run.

5 Correctly sized biomass is loaded into the reactor and safe working level
maintained.

6 There is water in the top cover water seal when the top cover is shut.

7 Reactor is loaded with biomass regularly and during shut off.

8 There is charcoal available at least 1 metre above the air nozzle before the start
of the run (if the gasifier is run for the first time or after unloading, the reactor
should be completely filled with dry char coal).

9 Water at indicated flow rates flows through the coolers and scrubbers.

10 Diesel at indicated flow rates flows through the DCC. Maintain the pressure drop
at 120mm to 150mm WG at all times across the DCC.

11 The flame is ignited at start-up only when the O2 level in the gas is below 2%.

12 Dust from the dry cyclone is removed/ discharged once every 24 hours of
operation.

13 Particulate matter in the diesel in the DCC is removed periodically using

centrifuge.

14 Pressure Sand filter in the Water Treatment is backwashed as prescribed.

15 Only Demineralised Water is supplied to the Central Air Nozzle jacket.

16 The recording of operating parameters as per Reporting Format is done

regularly.

33 OPERATIONS & MAINTENANCE MANUAL

DON’TS
Do not

1) Pour water into the reactor under any circumstance, to shut off the reactor.

2) Use larger sized wood chips than that specified.

3) Expose the bottom of the reactor to atmosphere when the reactor is hot.

4) Operate the gasifier at higher load/flow rate immediately after fresh start. Then
there is a possibility of biomass not totally converting into char by the time it reaches
the air nozzle. Hence follow start up procedure meticulously.

34 OPERATIONS & MAINTENANCE MANUAL

 APPENDIX III - UNLOADING THE REACTOR

The reactor has to be unloaded once the pressure drop across the reactor shoots
beyond 350-400 mm of WG. It is better to allow the reactor to cool down, say a day,
before attempting unloading. Additional care has to be exercised while handling as
the reactor bed could be hot and may cause injury/burns.

35 OPERATIONS & MAINTENANCE MANUAL

 APPENDIX IV - GASIFIER SPECIFICATIONS

SR. PARAMETER DETAILS

NO.

1. Power rating 300 kg/hr

2. Gasifier type Open top, down draught

3. Reactor Ceramic tiles + hot face insulation + cold face

insulation bricks with outer mild steel cylinder

4. Feed stock Any sun dried solid biomass whose density is over 300
kg/m3, having moisture content of 10 - 15%, max
(20%)* cut to sizes up to 150 mm - a mix of sizes
upwards of 25 mm. Briquette of any agro residue mix

5. Turn down ratio 4:1

6. Gas composition CO : 20 +2 %; H2 : 20 + 2%, CH4 : 3 + 1%, CO2 : 12

+ 1% and rest, N2

7. Lower calorific 4.8 + 0.2 MJ/m3

value of gas

8. Cooling water 300 - 550 LPM

9. Filter Water scrubber + cyclone

10. Wood 300 kg/hr at 100 % capacity

consumption rate

11. Application To be used as a fuel gas replacement for LDO in Heat

Treatment Furnaces
(* The high moisture biomass should be loaded only after five hours of start)

36 OPERATIONS & MAINTENANCE MANUAL

 APPENDIX V - MAINTENANCE SCHEDULE

< 24 hrs 140 to 150 hrs 500 to 700 hrs > 2500 hrs
1. Shut down 1. Open and scrape out 2. Remove and check for 1. Replace
the gasifier, adhered particles in: damages on central air Gear Oil
open the a. Direct cooler nozzles nozzle water jackets. (SAE ISO
bottom b. Water scrubber Replace if damaged. Grade 150)
flanges and c. Diesel scrubber and filter TIME 2 HR of Screw
remove dust d. Inside of flame trap. Conveyor
particles from TIME 8 HR. 3. Remove and check for Geared
dry cyclone. damages on secondary air motor after
TIME 20 MIN. 2. Empty left over charcoal nozzles, and replace first 50/100
from ash extraction sealed nozzles as required hrs of
2. Open and tank. TIME 4 HR geared
drain water TIME 4 HR. Motor
from wet 3. Change water for the top 4. Tighten all nuts & bolts of operation
cyclone cover seal. all system components. and after
TIME 5 MIN. TIME 10 MIN TIME 4 HR every 12
months
3. Open and 4. Grease ash extraction 5. Replace 50 % water in thereafter.
release bearing housings with SAE the Main Cooling Water TIME 8 HR
moisture from sufficiently Sump and Wash Water
moisture trap TIME 10 MIN Sump should the quality of 2. Unload
every 3 hours water deteriorate. the reactor
TIME 5 MIN. 5. Open and check for TIME 3 HR & check
loosening of nuts and bolts in thoroughly
4. Back wash bucket elevator. 6. Make up Gear Oil to for
Sand Bed TIME 4 HR required level in the Screw damages
Filter every 4 6. Open and clean foot valves Conveyor Geared Motor. on high
hrs. of main cooling water, wash TIME 1HR alumina
TIME 10 MIN. water and treatment plant tiles.
pumps. TIME 2 HR Replace
the tiles in
7. Clean all holes on the case of
cooling tower water damage.
distribution headers TIME 24 HR
TIME 1 HR

37 OPERATIONS & MAINTENANCE MANUAL

 APPENDIX VI - REPORTING FORMATS
Dat Tim Bioma Static Static Static Pressu Pressu Ash No. of
e e ss pressu pressu pressu re drop re at extracti Furnace
charge re at re at re at across the on s
d the gas Water Water DCC Blower duration connect
outlet scrubb cooler outlet ed
er inlet dump

38 OPERATIONS & MAINTENANCE MANUAL