商丘市海琦机械设备有限公司
Shangqiu Haiqi Machinery Equipment Co., Ltd.
2MW Gasification Power Plant
From: Jenkin
Shangqiu Haiqi Machinery Equipment Co., Ltd
1. Introduction
This section deals with the description, the objectives and the proposed results for the 2000KW Biomass Gasification Power Project to be established by Shangqiu Haiqi Machinery Equipment Co., Ltd.
1.1 Project description
1.1.1Project Activity and its Purpose
Biomass Gasification is the process of converting Biomass into a combustible gas mixture called Producer Gas. A Biomass Gasifier based Power Generation System uses Producer Gas to run engines (similar to Diesel Gensets) and generate power.and the same times, also use the biomass gasifier for electricity.
This method of power generation effectively improves the energy efficiency of Biomass and simultaneously reduces the environmental hazards that stem from conventional burning.
The proposed project will be of 2000kw capacity.
1.1.2Project Outputs
Generating 14.4 Million kWh (units) per year (300days) of electricity forexporting to the State grid
1.1.3Project Stakeholders
Shangqiu Haiqi Machinery Equipment Co., Ltd (Haiqi) -a Global Technology leader dealing in Renewable Energy Technologies for over more than 10 years and pioneers in the area ofBiomass Gasification & Biogas Systems.
2Technology
Biomass gasification is basically conversion of solid fuels (such as PE , PET , wood/ wood-waste, agricultural residues etc.) into a combustible gas mixture normally called Producer Gas. The process is typically used for various biomass materials and it involves partial combustion of such biomass Partial combustion process occurs when air supply (O2) is less than adequate for the complete combustion of biomass.
2.1Gasification
The gasifier is essentially a chemical reactor where various complex physical and chemical processes take place. Four distinct processes take place in a gasifier are:
Biomass is fed into gasifier at specified intervals. The equipment is designed in such a way that it takes in air in controlled quantities, resulting in partial oxidation of biomass into Producer gas.
One kg of Wood(others material is different, according to heat value) gets converted into 2.5 to 3.0 Nm3 of gas with a calorific value of 1100-1300Kcal per Nm3, which would have the following composition:
CH4 / C2H6 / C2H4 / C3H89.77 / 1.75 / 4.68 / 0.33
C3H6 / C4H10 / C4H8 / C5H12
2.33 / 0.07 / 0.76 / 0.02
C5H10 / H2 / CO2 / CO
0.26 / 12.95 / 36.39 / 30.69
2.2 Advantages of Gasification
It converts a traditional low quality fuel that is inconvenient to use into high quality, convenient, combustible gaseous fuel. Such conversion is at relatively very high efficiency and results in total convenience and process control.
--- Almost all environment pollution associated with biomass use can be eliminated. It is environment-friendly and reduces the threat of global warming.
--- Both initial investment and also the cost of energy/ power production are just about the lowest among all known alternatives as it is based on locally available resources with reasonable price stability.
--- As this is a renewable technology, there are a number of incentives available from the governments. Gasifiers are eligible for Carbon Credits under the Clean Development Mechanism and the rising cost of these credits could make the payback for the system much faster.
2.3 Indicative System Schematic – Gasifier and cleaning system:
There will be some conveying systems feeding Biomass to the gasifier. (Not indicated in the schematics)
BC – Belt conveyor: the solid fuel(biomass) will go inside of gasifier furnace through this.
G – Gasifier: Biomass is fed into this. Through a series of chemical processes, the solid fuel (biomass) is converted to a gaseous fuel (Producer Gas). The gas at the outlet will have some ash and char particulates and will be at above 400 degrees C.
C – Cyclone: This is used to arrest the large particles entrained in the gas generated from the gasifier.
WBDR – water-bath dust removal : This is used to cool the gas to about ambient temperature. At the same time, the gas is also cleaned by water impingement, remove the ash and tar.
OWS – oil water separator: Separate the water and wood tar from gas, at the same time remove the tar and water of the gas. In the process, it also cool the gas.
F1 – No.1 filter: This is a Biomass filter that considerably cleans up the gas. This has a proprietary mechanism that allows the Biomass to be rejuvenated periodically. The Biomass will need to be periodically changed. And for the used wood chips, after drying, we also can use them for the gasifier.
F2 – No.2 Filter: This is another Biomass filter in series that helps in further gas cleaning. This does not have any active mechanism. The Biomass will need to be periodically changed.
HPF – high pressure fan: This provides the motive power to the whole system. This creates suction in the gasifier which in allows controlled air entry (the control is through the system design) into the system. Thus the biomass is partly burnt and partly reduced to generate Producer Gas.
WS – : water seal: avoid the gas reback to the front.
DS – drying system: This used to cool the gas thus removing moisture from the same. This also increases the volumetric efficiency in the engines as the gas is cooler.
F3 – Safety Filter: This is a fabric filter. This acts as a safety before the gas goes into the engine genset.
Noted: we use water cooling system for the gasifier system and cleaning system. All parts are interlayer. The water is circulating, and we also can get waste heat from the hot water, use the heat for warming or greenhouse.
2.4 Disposal of the waste:
The following are the wastes generated by the gasifier:
Ash
This is about 3 – 5% by weight of the Biomass fed into the gasifier. This can also be used for making fly ash bricks.
Sludge
This is again ash mixed with some water. This can also be added to the soil.
Wood tar
After cleaning the gas, 20%-30% Heavy oil will be filtered by filters. And a little quantity will flow out with the water. We have sewage treatment system, we add active and sand inside of the treatment, the treatment is closed. After cleaning, then the waste water can flow outside. it can meet the environmental requirements. The heavy oil can be sold , the price ar round 340Usd per ton in China .the heavy oil also can burn mixed with industry oil using heavy oil burner
There are no other liquid/ gaseous effluents. The engine exhaust is very clean and the water is used in recirculation mode.
2.5 Effluent / Gaseous Emission/ Environmental Related
There are no harmful effluents from gasifier. Water is re-circulated in interlayer system from cooling pond to gasifier and from cooling tower to gas cleaning system. One has to replenish water pond to compensate evaporation losses and that depends upon no. of units generated in a day. Usually, ½ liter of water per unit of electricity generated is to be added as make up water. Water for engine cooling is to be added as per the specification of engine manufacturer given in their O & M manual. Any mud free water can be used for gasifier cooling pond and hence, it does not require any special water treatment but occasionally pH of water is to be maintained at desired level.
The other discharges from gasifier are charcoal and ash. Both are of biological nature and biodegradable. dry charcoal can be used again in gasifier while rest can be usedas an activated carbon in air dryer or as earthing material in electrical towers/ connections. Ash can be used as filling materials in large pits. Briquettes of ash can also be made and sold as fuel cake.
Gas from gasifier is fed directly into engine without any atmospheric discharge while flare is given to occasionally check the quality of the gas generated in gasifier and during the stoppage of the system.
The major gaseous emission from the power pack is from engine exhaust only. Exhaust from gas engine using producer gas is cleaner than conventional fuel due to absence of sulphur in biomass. Below are the indicative figures:
Emissions with Producer Gas:
Gas / Permissible limits as per CPCB norms / Emission ObservedCO / 1.2 g/MJ / 0.4 – 0.6 g/MJ
NOX / 2.2 g/ MJ / 0.7 g/MJ
Hydro carbons / 0.3 g/MJ / 0.005 g/MJ
Particulate matter / 0.2 g/MJ / 0.005 g/MJ
2.6 Technical Specifications Snapshot
For the Power Plant of 2000KW size, the Gasifier model would be 4unitsHQ-3000, and its technical specifications are appended below:
Gasifier Model / HQ-3000Gasifier Type / Down Draft
Fuel Specifications / Biomass
Size (mm) / Minimum:
Diameter (∅) – 10 mm; Length (L) – 30-50mm
Maximum: ∅ − 75 mm; L – 75 mm
Moisture Content (%) / 15% (Wet Basis)
Gasifier Output
Rated Gas Flow (Nm3/hr) / 3000-3400
Average Gas Calorific Value (Kcal/Nm3) / about 1300Kcal/m3
Rated Thermal Output (Kcal/hr) / 4,000,000
Maximum Biomass Consumption (Ton/hr) / 500-600 kg/hr
Gasification Temp. (°C) / 700-800
Indicative Gasification Efficiency (%)
Gasifier system / > 85%
Temperature of Gas at Gasifier Outlet (°C) / 150 to 200°C
Biomass Feeding
Mode / Belt conveyor
Frequency / Depending on the gasifier system we designed
Ash Removal / Continuous through proprietary control and water seal/ Dry Ash Char Removal System
Gas Cooling / Through water cooling system, water-bath dust removal system,oil water separator, ect.
Gas Cleaning / Through proprietary & patented fine filters
Start-Up / Through high pressure fan
3Project Details
3.1Biomass
3.1.1Primary Fuel
The primary fuel would be Biomass. Very conservatively, sustained biomass requirement for the proposed project would be less than 50ton per day.
The Biomass that would be cut from the fields by the laborers / farmers or by the interested parties would have to be sized in the threshers and then transported regularly.
3.1.2 Alternate Fuels:
If required other plastic waste , PE , PET ...., Woody Biomass like any fire wood, (Branches & Twigs), Wood Chips, Coconut shells, Cashew shell Cake, Corn cobs, Bamboo pieces, Groundnut shells, Soy Stalks, Saw Dust , plastic waste (Not alone but approximately 20% can be mixed with wood pieces and can be used in the Gasifier), etc. with moisture content less than 15%.
3.2Wood chips
Feedstock preparation is one of the most vital stages in ensuring production of desired quantity and quality of gas. Relatively dry and properly sized Biomass is necessary for Gasification to be efficient. The biomass would be sized as per specification and dried to bring down the moisture content to less than 15%.
In ‘Haiqi’ HQ Gasifiers, the fuels that can be used are wood pieces/ chips, coconut shells, corn cob etc. Partial quantities of cotton stalk (up to a maximum of 30%) or sawdust (up to a maximum of 10%) can also be mixed with wood and plastic waste 20% .The moisture contents in all these feeds should be limited to 20% or lesser.
The wood preparation and handling systems offered by ‘Haiqi’ as options are designed to ensure regular flow of firewood to the gasifier.
Out of the total quantity of biomass, 10-15% could be extracted as Charcoal. The charcoal so obtained would be sold different price in different place.
3.3Power Evacuation
The power generated by the plant would be at a voltage of kV. The voltage will be stepped up to kV and parallel with national grid at the same voltage level. The power national grid substation is within 2kms from the Biomass gasifier power plant.
3.4Sale of power to the Grid
The power generated by the plant would be supplied to the national Grid @ EUper unit generated. The generated power will be fed to KV feeder line through power evacuation equipment.
3.5Shed for Power Plant-cum-Godown
For the system, we will give steel structure, you need to build a house for the gen set. For the gasifier furnace, you can add a shed for it. For the raw material, you need to build shed for storing them.
3.6Essential Services
3.6.1Water:
The water required for the factory is sufficient through bore well. The cost of rigging the bore well and the pump set for the same has been included in the civil structure estimates.
3.6.2Effluents:
The design and technology provided has made necessary arrangements for disposal of effluents discharges during the process of production.
4 2000KW proposal and related specifications and main parts list
Shipment terms (Incoterms 2012): FOBQingdao
Containers:
Production time: 90 working days
№ / description / Power(KW) / quantity / Total price: FOBQingdao1 / Gasification plant / 2000KW / 1 sets / 2,656,250 USD
- Final USD value subject to updating exchange rate.
B. PAYMENT TERMS:
+ First: +40% will be paid by T/T in advance after signing the contract.
+ Second:+60% will be paid by T/T before loading.
C. The buyer should provide double tickets, food, accommodation, Local traffic in buyer's
country and accident assurance for seller’s engineers during installation and commissioning.
5 Specifications of gasification Power plant
- Gasification system
No / Name / Model / Power (KW) / Qty (Unit)1 / Bucket conveyor / HQ-3000 / 1.5 / 1
2 / Blender / // / 3 / 1
3 / Hydraulic pump / 4 / 1
4 / Lubrication oil pump / 0.04 / 1
5 / Gasifier furnace / HQ-3000
Dia3000*13000 / // / 1
6 / Water pump of gasifier furnace / // / 3+1.5 / 1
7 / Ash discharge / 4 / 1
8 / Water sprinkler / HQ-III / // / 1
9 / Condenser / HQ-III / // / 1
10 / Draught fan / 9-26-5.6C / 22 / 1
11 / Cyclone dust collector / 4 cyclones / // / 1
12 / Tube type cyclone separator / HQ-III / // / 4units
13 / Draught fan / 9-26-5.6C / 22 / 1
14 / Cyclone dust collector / 4 cyclones / // / 1
15 / Condenser / HQ-III / // / 1
16 / No.1 filter / Plastic ball / // / 1
17 / No.2 filter / clapboard / // / 1
18 / Condenser / HQ-III / // / 1
19 / No.3 Filter / Air filter / // / 1
20 / Gas tank / HQ-III / // / 1
21 / Control panel / PLC / // / 1
22 / Water pump for gas cleaning system / 7.5 / 1
23 / Steel structure / 1
24 / Cooling tower / 50ton / // / 2
- Gen set 500KW
Item / Technical parametersEngine / Model / 8300D/M-2
Gas mix mode / Inline water-cooled, four stroke, spark plug, open combustion chamber
unsupercharged
Cylinder number / 8
Cylinder diameter(mm) / 300
Rated speed(r/min) / 600
Rated power(KW) / 550
Heat consumption(MJ/kw.h) / 120
flywheel rolling direction / clockwise
Starting mode / Air motor start-up
Exhaust temperature(℃) / ≤600
Gas pressure(kPa) / ≥2.5
Gas temperature before going into the engine(℃) / ≤40
oil consumption(g/kW.h) / ≤1.0
Generator / Model / 500GFM
Rated power(KW) / 500
Voltage(V) / 11000
Current (A) / 902/57/34
Power factor(COSФ) / 0.8(lag)
Exciting mode / brushless
Phase / Three phase four wire
Size(L×B×H) / 6400*1600*2900mm
weight / 22000kg
Noted: 2MW system includes 4 sets gasifier furnace, 2 sets gas cleaning system and 4 sets 500KW gen sets.
The 2MW power plant will consume about 2ton Biomass fuel per hour (50ton 24hours/day).
河南省商丘市凯旋北路108号 Fax：+86-370-2311466 商丘海琦 1 / 12
Tel：+86-15539777130 Shangqiu Haiqi Machinery