Abstract: A waste-to-energy plasma system was designed by Necsa for commercial use to create electricity from unsorted municipal waste. Fly ash particles must be removed from the syngas stream at operating temperatures of 1000 °C and recycled back into the reactor for complete combustion. A 2D2D high efficiency cyclone separator was chosen for this purpose. During this study, two cyclone design methods were explored: The Classic Empirical Method (smaller cyclone) and the Flow Characteristics Method (larger cyclone). These designs were optimized with regard to efficiency, so as to remove at minimum 90% of the fly ash particles of average size 10 μm by 50 μm. Wood was used as feed source at a concentration of 20 g/m3 syngas. The two designs were then compared at room temperature, using Perspex test units and three feed gases of different densities, namely nitrogen, helium and air. System conditions were imitated by adapting the gas feed velocity and particle load for each gas respectively. Helium, the least dense of the three gases, would simulate higher temperatures, whereas air, the densest gas, simulates a lower temperature. The average cyclone efficiencies ranged between 94.96% and 98.37%, reaching up to 99.89% in individual runs. The lowest efficiency attained was 94.00%. Furthermore, the design of the smaller cyclone proved to be more robust, while the larger cyclone demonstrated a stronger correlation between its separation efficiency and the feed temperatures. The larger cyclone can be assumed to achieve slightly higher efficiencies at elevated temperatures. However, both design methods led to good designs. At room temperature, the difference in efficiency between the two cyclones was almost negligible. At higher temperatures, however, these general tendencies are expected to be amplified so that the difference between the two design methods will become more obvious. Though the design specifications were met for both designs, the smaller cyclone is recommended as default particle separator for the plasma system due to its robust nature.
Abstract: Boiler coals with low fixed carbon and higher ash content have always challenged the metallurgists to develop a suitable method for their utilization. In the present study, an attempt is made to establish an energy effective method for the reduction of iron ore fines in the form of nuggets by using ‘Syngas’. By devolatisation (expulsion of volatile matter by applying heat) of boiler coal, gaseous product (enriched with reducing agents like CO, CO2, H2, and CH4 gases) is generated. Iron ore nuggets are reduced by this syngas. For that reason, there is no direct contact between iron ore nuggets and coal ash. It helps to control the minimization of the sulphur intake of the reduced nuggets. A laboratory scale devolatisation furnace designed with reduction facility is evaluated after in-depth studies and exhaustive experimentations including thermo-gravimetric (TG-DTA) analysis to find out the volatile fraction present in boiler grade coal, gas chromatography (GC) to find out syngas composition in different temperature and furnace temperature gradient measurements to minimize the furnace cost by applying one heating coil. The nuggets are reduced in the devolatisation furnace at three different temperatures and three different times. The pre-reduced nuggets are subjected to analytical weight loss calculations to evaluate the extent of reduction. The phase and surface morphology analysis of pre-reduced samples are characterized using X-ray diffractometry (XRD), energy dispersive x-ray spectrometry (EDX), scanning electron microscopy (SEM), carbon sulphur analyzer and chemical analysis method. Degree of metallization of the reduced nuggets is 78.9% by using boiler grade coal. The pre-reduced nuggets with lesser sulphur content could be used in the blast furnace as raw materials or coolant which would reduce the high quality of coke rate of the furnace due to its pre-reduced character. These can be used in Basic Oxygen Furnace (BOF) as coolant also.
Abstract: Biomass briquette gasification is regarded as a
promising route for efficient briquette use in energy generation, fuels
and other useful chemicals. However, previous research has been
focused on briquette gasification in fixed bed gasifiers such as
updraft and downdraft gasifiers. Fluidised bed gasifier has the
potential to be effectively sized to medium or large scale. This study
investigated the use of fuel briquettes produced from blends of rice
husks and corn cobs biomass, in a bubbling fluidised bed gasifier.
The study adopted a combination of numerical equations and Aspen
Plus simulation software, to predict the product gas (syngas)
composition base on briquette density and biomass composition
(blend ratio of rice husks to corn cobs). The Aspen Plus model was
based on an experimentally validated model from the literature. The
results based on a briquette size 32 mm diameter and relaxed density
range of 500 to 650kg/m3, indicated that fluidisation air required in
the gasifier increased with increase in briquette density, and the
fluidisation air showed to be the controlling factor compared with the
actual air required for gasification of the biomass briquettes. The
mass flowrate of CO2 in the predicted syngas composition increased
with an increase in air flow, in the gasifier, while CO decreased and
H2 was almost constant. The ratio of H2 to CO for various blends of
rice husks and corn cobs did not significantly change at the designed
process air, but a significant difference of 1.0 was observed between
10/90 and 90/10 % blend of rice husks and corn cobs.
Abstract: Partial oxidation (POX) of light hydrocarbons (e.g.
methane) is occurred in the first part of the autothermal reformer
(ATR). The results of the detailed modeling of the reformer based on
the thermodynamic model of the POX and 1D heterogeneous
catalytic model for the fixed bed section are considered here.
According to the results, the overall performance of the ATR can be
improved by changing the important feed parameters.