A PATH FOR HORIZING YOUR INNOVATIVE WORK … - MECH 162.pdfused with a simple cleaning arrangement for gas to get producer gas quality suitable for use in an IC engine. Downdraft gasifiers

Research Article Impact Factor: 0.621 ISSN: 2319-507X Ganesh Nerkar, IJPRET, 2014; Volume 2 (9): 195-209 IJPRET

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INTERNATIONAL JOURNAL OF PURE AND APPLIED RESEARCH IN ENGINEERING AND

TECHNOLOGY A PATH FOR HORIZING YOUR INNOVATIVE WORK

PERFORMANCE OF C.I. ENGINE WITH DOWNDRAFT GASIFIER USING SWCS AND GS SOLID BASED AGROWASTE

GANESH A. NERKAR1, SWAPNIL A. PANDE2

1. M.E. Student, IBSS, COE, Amravati. 2. Assistant Professor, IBSS, COE, Amravati.

Accepted Date: 27/02/2014 ; Published Date: 01/05/2014

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Abstract: An attempt is made to compare usage of different biomass to generate producer gas and then to study the performance and from a dual fuel engine run on diesel and producer gas from different biomass. The down draft gasification system is used to generate producer gas through bio-gasification process. A compression ignition engine was allowed running on Diesel, Diesel and producer gas (Diesel + PG) dual fuel mode. In dual fuel mode, the producer gas from different Biomass viz. Subabul woodchips, coconut shell and groundnut shell used each time during experimentation. The producer gas generated through the process of gasification from bio-mass such as wastes from agricultural products, Subabul wood chips, coconut shells, groundnut shell, etc can be considered as alternative fuel for C.I. engines. In this work the C.I. Engine (10HP Single cylinder), is operated in the dual fuel mode (Diesel + Different Producer gas). Initially the engine was operated on diesel and the base line performance of the engine was evaluated for different loading condition, here keeping the engine speed constant. Then engine is shifted on dual fuel mode by supplying the producer gas mixed with fresh air. The performance of the CI engine is attempt for dual fuel mode in term of brake thermal efficiency, specific energy consumption, exhaust gas temperature and smoke density compared with the base line performance of the engine. Based on performance analysis, it is concluded that coconut shell is the best suitable fuel for gasifier compared to the other two biomass shell materials

Keywords: Downdraft Gasifier; C.I. Engine; Producer Gas; Dual Fual Mode.

Corresponding Author: MR. GANESH A. NERKAR

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Ganesh Nerkar, IJPRET, 2014; Volume 2 (9): 195-209

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INTRODUCTION

In the past few decades, biomass gasification has emerged as a promising route to efficient utilization of biomass, a renewable energy source which is widely available in tropical countries like India. This involves conversion of the biomass, a solid fuel, into a gaseous fuel called the producer gas. The producer gas can either be burnt in a burner for thermal applications such as furnaces or can beused in an internal combustion (I.C.) engine as a substitute for petroleum based fuels, to get motive power or electricity. being increasingly looked upon as viable alternative to provide electricity and motive power to the remote rural areas of our country. Availability of electricity can, in turn, act as a catalyst for promoting rural industrialization and development. While commercial systems of this kind are already available, many organizations have put inefforts to make simple low cost gasifiers, fabricated locally. In the same spirit Navree Energy Research and Information (NERI), an NGO, developed a gasifier-engine system and tested it in the field for running a flour mill and an irrigation pump, for more than a year [1, 2].

Gasification is a process converting solid/liquid fuel into gaseous fuel, known as producer gas, without leaving any solid carbonaceous residue. The producer gas is the mixture of carbon monoxide, hydrogen, methane and nitrogen. Abundant quantities of agricultural wastes like subabul woodchips, coconut shell, groundnut shell etc. are produced worldwide every year and these are now underutilized. The major portion of these wastes undergoes natural decomposition resulting in production of various green house gases and other environmental problems. Biomass gasification is one of the biomass conversion technologies to produce a combustible gas mixture (called producer gas) using agro residue. Biomass gasification can be effectively utilized for decentralized power generation and thermal applications. The gasifier is essentially a chemical reactor where various complex physical and chemical processes take place that include drying, heating, pyrolysing, partial oxidation and finally reduction as it flows through it. Pyrolysis is the heating process, which produces both charcoal and tar and combustion is complete oxidation of fuel. Gasification process is in between pyrolysis and combustion. Gasifier can be broadly classified into three according to the gas flow direction, that is, up draft, down draft and cross draft gasifier times [3-7].

Fig 1: Gasification Processes



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II. DETAILS OF GASIFIRE

A. Biomass Gasifiers

Complete combustion of any biomass should result in formation of carbon-dioxide and water vapour, with ash as a residue. On the other hand, in a biomass Gasifier, the biomass is burnt in limited supply of oxygen, not sufficient for complete combustion. This results in the formation of a combustible mixture containing carbon-monoxide, hydrogen and methane, besides the non-combustible components of carbon-dioxide and water vapour [8].

FF

FIg. 2: Experimental set up of downdraft gasifier

B. Types of Gasifire

Most of the Gasifier in the field is of two types:

(i) Up draft type where the gas flow is upwards through the biomass and char bed, while the biomass moves down[9].

(ii) Down draft type where the gas also flows downwards, in co-current with biomass. The down draft types of design gives much less tar in the final gas as compared to the updraft design. Hence, up draft Gasifier are more commonly used for thermal applications. If charcoal is used as feedstock in the gasifier, the tar produced is much less since most of the volatile components of biomass causing tar formation have already been removed at the time of charcoal formation. Consequently a simple updraft gasifier of charcoal can be used with a simple cleaning arrangement for gas to get producer gas quality suitable for use in an IC engine. This is the strategy adopted by NERI in developing their simple system for power generation [10]. The



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internal diameter in most downdraft gasifier is reduced in order to create throat. Air inlet nozzles are commonly set radially round the throat to distribute air as uniformly as possible. (Fig.2) Schematic view of a downdraft gasifier [11, 12]

C. Downdraft Gasifier

Gasifiers are the reactors in which gasification of solid fuel takes place giving Producer gas. This gasification is carried out in different types of gasifier. These are downdraft, updraft and cross draft, and fluidized, entrained bed, rotary and inclined rate. The most common gasifier is the downdraft or co-current type [13].

fig. 3: Schematic view of a downdraft gasifier.

In Schematic view of a downdraft gasifier. Down draft type where the gas also flows downwards, in co-current with biomass. The down draft a type of design gives much less tar in the final gas as compared to the updraft design. The pyrolysis zone is above the combustion zone and the reduction zone below it. Fuel is fed from the top and the air flows in the downward direction through the combustion and reduction zones. Movement of air is in the same direction as that of the fuel [14]

D. Selection of Gasifier

Gasifier is good alternative sources than any other type of fuel. Consider fossil fuel with contain some amount of sulfur with react with oxygen to form sulfur-dioxide which is corrosive and



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may damage the engine parts. Among all gasifiers downdraft gasifier is good for application on IC engine for following reasons:

Updraft gasifier produce 5 to 20% volatile tars oils and so are unsuitable for operation of the engine.

Downdraft gasifiers typically produce less than 1% of tar and so are used widely for engine operation.

Fluidized bed gasifier uses coal as the raw material because if the material is fluidized with oxygen and thus the temperature is low and material required to be reactive thus the cost is higher and again tar contain is higher as compared to downdraft gasifier [15].

Material we used may contain volatile oil which look like water to our naked eye then downdraft gasifier helps to break or to reduce the percentage of the volatile material in the gas.

The size of gasifier unit is smaller in case with downdraft gasifier [16].

ANALYSIS OF DOWN DRAFT GASIFIRE

A. Details of Gasifier Specification

Downdraft wood waste gasifier, Associated Engineering Work (AEW) make having the technical collaboration with SPRERI is used for generation of producer [17].

Table I: SPECIFICATION OF DOWN DRAFT GASIFIER

Gasifier Unit

Type Of Gasifier Downdraft, batch feeding

Model GM 55

Material of

Construction

Generally M.S. except hearth and air Nozzles where S.S. is used

Rated capacity 10 to 12 m3 /hour

Air Nozzles 4 Nos.



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Downdraft gasifiers (Fig.3) have a long history of use in cars and buses to produce a Wood-derived gas for internal combustion engines. In a downdraft gasifier, air is introduced into a downward flowing packed bed or solid fuel stream and gas is drawn off at the bottom. The air/oxygen and fuel enter the reaction zone from above decomposing the combustion gases and burning most of the tars [18]. Consequently a simple updraft gasifier of charcoal can be used with a simple cleaning arrangement for gas to get producer gas quality suitable for use in an IC engine. Downdraft gasifiers are not ideal for waste treatment because they typically require a low ash fuel such as wood, to avoid clogging [19].

B. Use of Producer Gas in Engine Producer gas can be used in I.C. engines in two ways

(i) In dual-fuel mode along with diesel in a compression-ignition (CI) engine and (ii) in single fuel mode in a spark-ignition (SI) engine. Till recently, most systems used dual-fuel mode of operation. In this mode, a diesel engine is run on the combination of producer gas and diesel. With the use of producer gas, the diesel requirement can be reduced to about 20% of the normal requirement in the pure diesel mode. The diesel requirement is higher when the engine is run in part load. Dependence on diesel for this mode of operation can pose a problem in regions where diesel is not of Producer Gas easily available [20]. More importantly, with the rising cost of diesel, the economics of this mode of operation may not be very favorable. On the other hand, operation of an engine only on producer gas requires spark-ignition. While a petrol

Hopper capacity 60 kg

Fuel used Waste woody biomass

Size of fuel Chips of 25 mm, 10mm

Gas cooling medium Water

Gas Clean Up Unit

Scrubber Direct contact, co-current water jet

Filter Media Pebble, cotton, yarn waste etc.

Scrubber water low Rate 600/hour

Pressure drop 45 mm of water column

Gas Temperature Ambient [after cooling]

Tar and Soot in gas Negligible



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engine can be directly used for the purpose, it has the disadvantage of a low compression ratio of 9:1 or lower. Producer gas can be used successfully on engines with a much higher compression ratio of about 17:1. Since efficiency of operation of an engine improves with increase in compression ratio, it is more advantageous to convert a diesel engine to run on spark-ignition mode. This involves replacing the injection system of a diesel engine by a spark plug and ignition system. The engine used in the present system is a spark-ignited engine that runs on producer gas alone, which has been converted from a commercial diesel engine [21].

C. General Applications

This system can be used for various applications requiring electric or motive power up to 4.5 kW, for example, a flour mill, an irrigation pump, and lighting purposes. Use can be made of the electric power output or directly the shaft power output of the engine. The producer gas obtained by the process of gasification can have end use of thermal application or for mechanical/electrical power generation [22]. Like any other gaseous fuel, producer gas has the control for power when compared to that of solid fuel, in this solid biomass..

D. Special features

1. Top and Open twin entry system ensure a better thermal environment compared to the conventional closed top model- relatively higher through put for the same reactor size and also better gas quality.

2. Available in modules upwards of 5 kg/hr to 1100 kg/hr.

3. Multi-fuel capability – forest & plantation residue, agro residue, RDF in briquetted form with maximum moisture content of 15%.

4. High gasification efficiency > 80%

5. Superior gas quality, suitable for turbocharged R/C engines [23].

6. Low cost of electricity generation and competitive with the grid tariff.

7. Environmentally sound – low NOx in the engine exhaust.

8. Value addition products ~ activated carbon, along with energy [24].

E. Composition of Producer Gas



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TABLE II. COMPOSITION OF PRODUCER GAS

F. Different Biomass Use in Downdraft Gasifier

1. Subabul Woodchips

2. Coconut Shell

3. Groundnut Shell

Figure 3: Size of diferrerent Agro-Waste

Constituents Percentage(%)

Carbon monoxide 18-22

Hydrogen 15-19

Methane 1-5

Hydocarbon 0.2-0.4

Nitogen 45-55

Water 4



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1) Coconut shell was used as the feedstock with size range 0.75-1.0 mm. The proximate and ultimate analysis of biomass as follows: moisture 10.53%, fixed carbon 13.10%, volatile matter 57.96% and ash 18.4%. The ultimate analysis was C 50.2 %, H 5.30%, N 0.0% and O 43.4%.

2) Ground nut shell has great potential for commercial use. It is used as fuel filler in cattle feed, hard particleboard, cork substitute, activated carbon etc. The Proximate analysis reveals that moisture 8.76%, fixed carbon 15.50%, volatile matter 54.96 and Ash 20.3%. The ultimate analysis shows that C 48.3 %, H5.70%, N 0.8 % and O 39.4%.

3) Subabul woodchips is recognized as an important source of energy, particularly in developing countries where it economies largely based on agriculture and forestry. Agriculture waste is one form of biomass which is readily available but is largely not utilized in energy recovery schemes. The proximate analysis and ultimate analysis of biomass as follows: moisture 7.9%, volatile matter 59.5%, fixed carbon 19.9% and ash 17.1%. The ultimate analysis was C 38.9%, H 5.1%, N 0.6%, and O 32.0%

IV. DETAILS OF GASSIFICATION IN DUAL FUEL MODE

Concept Use In Dual Fuel Mode

The engine was started at no load by pressing decompression lever and it was released suddenly when andthe engine was load cranked at sufficient speed. After the feed control was adjusted so that engine attain rated speed and allowed to run about (15 min) till the steady state condition was reached with the fuel measure unit and stopwatch time elapsed for the consumption of 10 ml of fuel was measured for three times and average of there was taken fuel consumption, RPM, density, load, voltage and on loading arrangement were also measured.

The engine was loaded step 1kW, 2kW, 3kW, and 4kW through electrical resistant loading kit arrangement, by Keeping engine speed constant by adjusting the feed control so that engine maintain its rated speed .

Biomass has been a major energy source, prior to the discovery of fossil fuels like coal and petroleum. Even though its role is presently diminished in developed countries, it is still widely used in rural communities of the developing countries for their energy needs in terms of cooking and limited industrial use. Biomass, besides using in solid form, can be converted into gaseous form through gasification route.

Discuss About Gasification Process



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Biomass is a natural substance available, which stores solar energy by the process of photosynthesis in the presence of sunlight. It chiefly contains cellulose, hemicellulose and lignin, with an average composition of C6 H10 O5, with slight variations depending on the nature of the biomass. Theoretically, the ratio of air-to-fuel required for the complete combustion of the biomass, defined as stoichiometric combustion is 6:1 to 6.5:1, with the end products being CO2 and H2O. In gasification the combustion is carried at sub-stoichiometric conditions with air-to-fuel ratio being 1.5:1 to 1.8:1. The gas so obtained is called producer gas, which is combustible. This process is made possible in a device called gasifier, in a limited supply of air [25].

Gasification is a two-stage reaction consisting of oxidation and reduction processes. These processes occur under sub-stoichiometric conditions of air with biomass. The first part of sub-stoichiometric oxidation leads to the loss of volatiles from biomass and is exothermic; it results in peak temperatures of 1400 to 1500 K and generation of gaseous products like carbon monoxide, hydrogen in some proportions and carbon dioxide and water vapor which in turn are reduced in part to carbon monoxide and hydrogen by the hot bed of charcoal generated during the process of gasification. Reduction reaction is an endothermic reaction to generate combustible products like CO, H2 and CH4 as indicated below [26].

Since char is generated during the gasification process the entire operation is self-sustaining.

V. TEST METHODOLOGY

A. Description of Experimental setup

The biomass is fed to the gasifire through its bottom opening. Air enters at the combustion zone and producer gas generated leaves near the bottom of gasifire. The hot producer gas is allowed to pass through the cooler where its temperature is reducing to atmospheric. The cooled gas with moisture is then passed through the filter to re remove tar and the other particles.

Layout of Experimental Set Up



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The experimental setup consists of a Downdraft Gasifier, Gas Cooled, Gas Filter, Diesel Engine and Centrifugal Pump System.

Figure 4. Schematic diagram of engine test setup.

The engine is modified to work in dual fuel mode by attaching a producer gas supply to the intake manifold. Under dual fual operation part of the solid is replaced by gaseous so as to maintain the power output of the engine the same as for normal diesel operating point diesel engine continuous to dominate the agriculture sector in our country in comparison to spark ignition engine and have always been preferred widely because of power developed, specific fuel consumption and durability. However, it would be worthwhile to inform that the fuel is burnt in diesel engine by self ignition at higher temperature and pressure conditions o the order of 6000 C and 45 bar, respectively. Diesel as a fuel is injected into the combustion chamber at the end of compression stroke and after certain ignition delay, it buns to give the motive Power. In India, almost all irrigation pump sets, tractors, mechanized farm machinery and heavy transportation vehicle are powered by direct injection diesel engines [27].

VI. RESULT & DISCUSSION

Variation In Sec With Break Power

The coconut shell has Low Specific Energy Consumption as compare to groundnut shell and subabul woodchips. Coconut shell is one of the waste biomass and easily available material. It is the best alternative energy source Coconut Shell material.



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Fig 5 : Variation of SEC w.r.t Engine

B. Variations in LFR with Break Power

The coconut shell has more Liquid fuel Replacement as compare to groundnut shell and subabul woodchips. Liquid fuel Replacement (Diesel Replacement) 10 to 15 % higher than groundnut shell and subabul woodchips in Coconut shell. The coconut shell has more thermal efficiency as compare to groundnut shell and subabul woodchips

Fig 6 : Variation of LFR w.r.t Break Power

VII. CONCLUSION

Combustible gases can be produced from coconut shell, ground nut shell and Subabul Woodchip; they were utilized as a feedstock in a down draft gasifier. I notice that, coconut shell

0

10

20

30

40

50

0 2 4 6

SEC

(MJ/

KW

hr)

BP (KW)

Diesel

0102030405060

0 2 4 6

LFR

(%)

BP (KW)

Diesel+PG(…



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is the best biomass fuel as compare to groundnut shell and subabul woodchips of below reasons.

The calorific value of the coconut shell is more than groundnut shell and subabul woodchips. Coconut shell is one of the waste biomass and easily available material. It is the best alternative energy source Coconut Shell material.

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A PATH FOR HORIZING YOUR INNOVATIVE WORK … - MECH 162.pdfused with a simple cleaning arrangement for gas to get producer gas quality suitable for use in an IC engine. Downdraft gasifiers