WO2014207755A1 - Zero effluent discharge biomass gasification - Google Patents

Zero effluent discharge biomass gasification Download PDF

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Publication number
WO2014207755A1
WO2014207755A1 PCT/IN2013/000707 IN2013000707W WO2014207755A1 WO 2014207755 A1 WO2014207755 A1 WO 2014207755A1 IN 2013000707 W IN2013000707 W IN 2013000707W WO 2014207755 A1 WO2014207755 A1 WO 2014207755A1
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WO
WIPO (PCT)
Prior art keywords
gas
tar
water
condenser
effluent
Prior art date
Application number
PCT/IN2013/000707
Other languages
French (fr)
Inventor
Subhash Savjibhai PADSUMBIYA
Salim Abbasbhai CHANNIWALA
Original Assignee
Padsumbiya Subhash Savjibhai
Channiwala Salim Abbasbhai
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Application filed by Padsumbiya Subhash Savjibhai, Channiwala Salim Abbasbhai filed Critical Padsumbiya Subhash Savjibhai
Publication of WO2014207755A1 publication Critical patent/WO2014207755A1/en

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    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
    • C10J3/02—Fixed-bed gasification of lump fuel
    • C10J3/20—Apparatus; Plants
    • C10J3/34—Grates; Mechanical ash-removing devices
    • C10J3/40—Movable grates
    • C10J3/42—Rotary grates
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B3/00—Hydrogen; Gaseous mixtures containing hydrogen; Separation of hydrogen from mixtures containing it; Purification of hydrogen
    • C01B3/02—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen
    • C01B3/32—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air
    • C01B3/34—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents
    • C01B3/38—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents using catalysts
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
    • C10J3/02—Fixed-bed gasification of lump fuel
    • C10J3/20—Apparatus; Plants
    • C10J3/30—Fuel charging devices
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
    • C10J3/72—Other features
    • C10J3/723—Controlling or regulating the gasification process
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
    • C10J3/72—Other features
    • C10J3/74—Construction of shells or jackets
    • C10J3/76—Water jackets; Steam boiler-jackets
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
    • C10J3/72—Other features
    • C10J3/82—Gas withdrawal means
    • C10J3/84—Gas withdrawal means with means for removing dust or tar from the gas
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
    • C10K1/00—Purifying combustible gases containing carbon monoxide
    • C10K1/04—Purifying combustible gases containing carbon monoxide by cooling to condense non-gaseous materials
    • C10K1/046—Reducing the tar content
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G5/00—Incineration of waste; Incinerator constructions; Details, accessories or control therefor
    • F23G5/02—Incineration of waste; Incinerator constructions; Details, accessories or control therefor with pretreatment
    • F23G5/027—Incineration of waste; Incinerator constructions; Details, accessories or control therefor with pretreatment pyrolising or gasifying stage
    • F23G5/0276—Incineration of waste; Incinerator constructions; Details, accessories or control therefor with pretreatment pyrolising or gasifying stage using direct heating
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G7/00—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals
    • F23G7/10—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals of field or garden waste or biomasses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B03—SEPARATION OF SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS; MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
    • B03C—MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
    • B03C3/00—Separating dispersed particles from gases or vapour, e.g. air, by electrostatic effect
    • B03C3/02—Plant or installations having external electricity supply
    • B03C3/16—Plant or installations having external electricity supply wet type
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/02—Processes for making hydrogen or synthesis gas
    • C01B2203/0205—Processes for making hydrogen or synthesis gas containing a reforming step
    • C01B2203/0227—Processes for making hydrogen or synthesis gas containing a reforming step containing a catalytic reforming step
    • C01B2203/0233—Processes for making hydrogen or synthesis gas containing a reforming step containing a catalytic reforming step the reforming step being a steam reforming step
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/10—Catalysts for performing the hydrogen forming reactions
    • C01B2203/1041—Composition of the catalyst
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/10—Catalysts for performing the hydrogen forming reactions
    • C01B2203/1041—Composition of the catalyst
    • C01B2203/1047—Group VIII metal catalysts
    • C01B2203/1052—Nickel or cobalt catalysts
    • C01B2203/1058—Nickel catalysts
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/12—Feeding the process for making hydrogen or synthesis gas
    • C01B2203/1205—Composition of the feed
    • C01B2203/1211—Organic compounds or organic mixtures used in the process for making hydrogen or synthesis gas
    • C01B2203/1235—Hydrocarbons
    • C01B2203/1252—Cyclic or aromatic hydrocarbons
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2200/00—Details of gasification apparatus
    • C10J2200/09—Mechanical details of gasifiers not otherwise provided for, e.g. sealing means
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2200/00—Details of gasification apparatus
    • C10J2200/15—Details of feeding means
    • C10J2200/156—Sluices, e.g. mechanical sluices for preventing escape of gas through the feed inlet
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0913—Carbonaceous raw material
    • C10J2300/0916—Biomass
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0953—Gasifying agents
    • C10J2300/0956—Air or oxygen enriched air
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0983—Additives
    • C10J2300/0989—Hydrocarbons as additives to gasifying agents to improve caloric properties
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/16—Integration of gasification processes with another plant or parts within the plant
    • C10J2300/1603—Integration of gasification processes with another plant or parts within the plant with gas treatment
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G2201/00—Pretreatment
    • F23G2201/30—Pyrolysing
    • F23G2201/301—Treating pyrogases
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G2201/00—Pretreatment
    • F23G2201/30—Pyrolysing
    • F23G2201/304—Burning pyrosolids
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G2201/00—Pretreatment
    • F23G2201/40—Gasification
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E50/00—Technologies for the production of fuel of non-fossil origin
    • Y02E50/10—Biofuels, e.g. bio-diesel
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00—Technologies relating to chemical industry
    • Y02P20/141—Feedstock
    • Y02P20/145—Feedstock the feedstock being materials of biological origin

Definitions

  • the present invention relates to the gasification system for any biomass such as wood, peat, shells, lignite, coal, coke etc.
  • the present invention relates to zero effluent discharge biomass gasification system which facilitates no effluent discharge to the environment.
  • the producer gas In biomass gasifier, the producer gas is produced. This gas contains moisture tar and particulates. Further, this gas leaks through series of connections and creates atmospheric pollution. The tar and particulates are usually removed through wet scrubbers and various filters. This produces contaminated effluent and filters which are finally discharged to the environment and creates environmental pollution.
  • Indian patent as per specification No. 92840 dtd.18th March 1964 deals with improvements relating to the gasification of finely divided solid fuels in suspension with oxygen or oxygen enriched air and if desired, water vapour.
  • the invention is applicable to such process when carried out at high pressure.
  • Indian patent as per specification No. 80239, 15th January 1962 deals with Method and apparatus for the gasification of solid fuels. This invention relates to the gasification of solid fuels by means of preheated oxygen or oxygen enriched air and steam in rotary grate gasifier.
  • Indian Patent specification No. 162145 dtd. 22nd February 1984 accepted on 9th April 1988 deals with Process for producing refractory bricks for lining of smalter coal gasifier for production of reducing gas for producing pig iron characterized in that the part of gasifiers "attacked by liquid slags" having a molar ratio of CaO/Si02 below 2 is lined with unburned carbonallors magnesia bricks produced by mixing of fused magnesia with sinter magnesia.
  • US Patent No. US 6,439135 Bl dated August 27, 2002 deals with Organic Waste Gasification Processing and the production of alternative energy sources.
  • This invention relates to the organic waste gasification processing using an Oxygen-starved (02-Starved) gasification process, and is also directed towards deriving alternative energy sources from by products produced by such a process.
  • It is basically a municipal waste gasification system comprising of plurality of primary gasification chambers for receiving municipal waste and operating one or more chambers to produce an effluent by an oxygen straved process in primary and secondary combustion chambers.
  • US state patent No. US 8,252,072B2 dtd. August 18, 2012 deals with a downdraft -updraft gasifier and method for the gasification of biomass and waste to produce combustible effluent, a novel gasification system and method incorporating the gasifier and a novel filter to produce tar and moisture free producer gas and a novel polymer for use in gasifier.
  • the present inventors have discovered that a gasifier having two oxidation zones, wherein in a first zone the gas flow is in a downward direction (in the same direction as the fuel flow) and in a second zone beneath the first zone the gas flow is upward (in the opposite direction to the fuel flow) addresses many of the operating difficulties in the known gasifiers.
  • Such a device may be called a "down-updraft gasifier" to reflect the combination of the down and up flow of the gas.
  • the main object of the present invention is to provide zero effluent discharge biomass gasification system which produce better quality, dry and clean producer gas from any biomass such as wood, peat, shells, lignite, coal, coke etc. through refiring of cracked tar gas and evapdfated effluent in oxidation zone of gasifier and thus offer zero effluent discharge gasification system.
  • Another object of the present invention is to provide zero effluent discharge biomass gasification system which facilitates a tar cracker cum effluent evaporator for zero effluent discharge and to refire this cracked tar gas and evaporated effluent into oxidation zone of gasifier to improve its performance and achieve truly zero effluent discharge.
  • Yet another object of the present invention is to provide zero effluent discharge biomass gasification system which facilitates indirectly cooled primary gas cooler cum settling chamber at exit of gasifier and final exit of the system to cool and produce dry and particulate and tar free producer gas to be used in any furnace, kiln, boiler or combustion chamber.
  • Yet another object of the present invention is to provide zero effluent discharge biomass gasification system which incorporate wet electrostatic precipitator (tar catcher) to remove the tar from the producer gas.
  • wet electrostatic precipitator tar catcher
  • Yet another object of present invention is to provide zero effluent discharge biomass gasification system which offer 100% indirect cooling for primary gas cooler-cum settling chambers at exit of gasifier, set of condensers and final gas cooler cum settling chamber at exit of whole gasification system to avoid any water contamination.
  • Yet another object of present invention is to provide zero effluent discharge biomass gasification system which produces a very small amount of activated carbon through steam reformation of tar in presence of Nickel / Tungston wire mesh as catalyst at exit section of tar cracker cum effluent evaporator.
  • Fig.1 Shows perspective view of the present invention
  • Fig.2 Shows enlarged front view of the present invention
  • Fig.3 Shows back view of the present invention
  • Fig.4 Shows top view of the present invention
  • Fig.5 Shows left hand side view of the present invention
  • Fig.6 Shows the cross- section view of gasifier
  • Fig.7 Shows the cross-section view of primary gas cooler cum settling chamber and indirectly cooled final gas cooler cum settling chamber
  • Fig.8 Shows the back view of two way water seal controlled valve A - 1 and two way water seal controlled valve - 2
  • Fig.9 Shows the front view of rotary tar kiln cum effluent A evaporator
  • the present invention relates to Zero effluent discharge biomass gasification system (100).
  • the present invention gasification system (100) is provided with gasifier (1) for producing the producer gas which is supported by a steel structure (26).
  • the gasifier (1) comprises of a shell which is immersed in water seal (le) which prevents air ingress to the gasifier (1) as well as avoids gas leakage to the atmosphere.
  • the gasifier (1) further comprises of top which is connected with double lock hopper system for feeding biomass.
  • the said double lock hopper feeding system which is fixed at the top of the gasifier (1) to feed the biomass is comprised of coal charger (20) and coal feeding hopper (21) which facilitates gas leak proof feeding to the gasifier ( 1).
  • the said coal charger (20) receives the biomass from coal feeding system (19).
  • the bottom of the said coal charger (20) is water sealed by water seal for coal charger (20a).
  • the biomass from the coal charger (20) delivers to coal feeding hopper (21) when the said coal feeding hopper (21) is empty.
  • the coal feeding hopper (21) supplies biomass to the gasifier (1) as per the requirements.
  • the bottom of this coal feeding hopper (21) is also water sealed by water seal for coal feeding hopper (21a).
  • the double lock coal feeding system (19) facilitates the feeding of biomass to the gasifier (1) without any gas leakage.
  • the gasifier (1) comprises of water jacket (lb) for receiving hot air supply from the hot air centrifugal blower (15) through air supply line (la).
  • the mixture of steam and air at about 60°C to 70°C from top side is fed through supply line (lc) below rotating grate (Id).
  • a twin lobe blower (22) is incorporated at the gasifier (1) for supplying high pressure air in case of chocking of gasifier (1).
  • the gasifier (1) comprises of oxidation zone (lg) for refiring evaporated effluent and cracked tar from rotary tar kiln cum effluent evaporator (1 1) through refiring system (If).
  • the said refiring system (If) is used for refiring of cracked tar and evaporated effluent effectively in the oxidation zone (lg) of gasifier (1) which helps in improving the efficiency of gasifier (1) ⁇
  • the producer gas generated in gasifier (1) goes to water sealed controlled gas shut off valve (25) which regulates or shut off the producer gas supply to the primary gas cooler cum settling chamber (2).
  • This producer gas has a high exit temperature, tar content and particulate matters.
  • This producer gas is indirectly cooled in this primary settling chamber cum gas cooler (2).
  • the present invention gasification system (100) is provided with indirectly cooled primary gas cooler cum settling chamber (2) which is attached after water seal controlled gas shut off valve (25) for receiving the hot producer gas from the gasifier (1), cooling the producer gas, settling down the particulates present in producer gas and furt er passing the relatively clean and cooled producer gas to tar catcher (3).
  • the said primary gas cooler cum settling chamber (2) is comprised of gas inlet (2f) for receiving the hot producer gas from the gasifier (1), upper metallic hopper (2a) to reduce the gas velocity for facilitating the settling of particles, series of cooling coils (2e) for cooling the producer gas, lower metallic hopper (2b) which acts as water seal cum particle collector, inlet water supply header (2c) to supply water to the series of cooling coils (2e), outlet water header (2d) to collect the hot water from the series of cooling coils (2e) and gas outlet (2g) for passing the relatively clean and cooled producer gas to tar catcher (3).
  • tar catcher (3) is provided for receiving relatively clean and cool gas from primary gas cooler cum settling chamber (2) for isolating the tar present in producer gas at bottom of tar catcher (3) as liquid tar.
  • the tar catcher (3) comprises of series of electrodes maintained at high potentials. The tar gets migrated to the electrodes due to high potential and flows down as liquid tar and deposited at the bottom.
  • two way water seal controlled valve- 1 (4) is provided for receiving relatively clean particulate and tar free producer gas from tar catcher (3) and direct the said producer gas to any one set of the gas condenser - 1 (5) and gas condenser -2 (6) or gas condenser -3 (7) and gas condenser -4 (8) depending on the availability. This provides ease of operation and maintenance without any gas leakage to the atmosphere avoiding the atmospheric pollution.
  • the said two way water seal controlled valve- 1 (4) mainly comprises of one gas inlet for receiving relatively clean particulate and tar free producer gas from tar catcher (3), water storage tank for storing water, upper water tank-2 (34) to control water level to supply gas in one of gas outlet, lower water tank - 1 (33) to control water level to supply gas in another gas outlet depending on requirements.
  • the pair of gas outlets direct the producer gas to respective set of gas condenser - 1 (5) and gas condenser -2 (6) and gas condenser -3 (7) and gas condenser -4 (8) depending on requirement.
  • the producer gas is directed to any one of the pair of gas outlet and thus provides flexibility of operation.
  • sets of gas condenser - 1 (5) and gas condenser -2 (6) and gas condenser -3 (7) and gas condenser -4 (8) are provided in parallel, with each set containing two condensers in series.
  • the said both set of gas condenser - 1 (5) and gas condenser -2 (6) and gas condenser -3 (7) and gas condenser -4 (8) in series are indirectly cooled through water circulated from cooling water pump (17) incorporated at induced draught air cooling tower (12) and thus, avoiding water contamination.
  • the condensed water which contains minor traces of tar also is collected in the bottom of each set of gas condenser - 1 (5) and gas condenser -2 (6) and gas condenser -3 (7) and gas condenser -4 (8).
  • the bottom and lids of both sets of gas condenser - 1 (5) and gas condenser -2 (6) and gas condenser -3 (7) and gas condenser -4 (8) are water sealed thus preventing both gas leakage and effluent leakage through each set of gas condenser - 1 (5) and gas condenser -2 (6) and gas condenser -3 (7) and gas condenser - 4 (8) facilitating zero discharge of effluent or gas to the atmosphere.
  • indirectly cooled final gas cooler cum settling chamber ( 10) is provided for receiving producer gas from any of the sets of gas condenser - 1 (5) and gas condenser -2 (6) or gas condenser -3 (7) and gas condenser -4 (8) through two-way water sealed controlled valve-2 (9).
  • the chilled water from water chilling plant (13) circulates through cooling coils in settling chamber (10) for indirectly cooling the producer gas below atmospheric temperature. This sub- cooling of producer gas makes the said producer gas a dry gas and residual water vapour along with tar gets condensed which is collected at the bottom of indirectly cooled final gas cooler cum settling chamber
  • a rotary tar kiln cum effluent evaporator (11) is provided for receiving a liquid tar which is collected in tar and tarry waste water storage tank (30) from the bottom of tar catcher (3).
  • High pressure tar pump (18) supplies the liquid tar from tar and tarry waste water storage tank (30) to the rotary tar kiln cum effluent evaporator
  • a burner (1 1a) is embodied in kiln which fires producer gas supplied from producer gas supply pipe to the tar cracker (29) which receives producer gas from producer gas supply pipe to the plant (31) and heats the tar cracker cum rotary kiln (l ib).
  • the air required to fire the producer gas in the burner (11a) in the rotary kiln (11) is supplied through a separate air supply blower for tar cracker (28).
  • the temperature of the rotary kiln (l ib) is maintained at 400°C to 500°C. Due to the high temperature the said tar gets cracked.
  • the cracked tar gas is taken into Nickel or Tungsto wire mesh catalyst (11c) incorporated at the kiln exit section (l id).
  • the cracked tar gas is fed to Nickel or Tungston wire mesh catalyst (1 1c) and exit of kiln (l id) where tar gets partially steam reformed to activated carbon, which is a valuable product.
  • the effluent evaporator (l ie) is integrated with the rotary kiln cum effluent evaporator (1 1) for receiving hot flue gases and for finally discharging to the atmosphere through an ID fan (27).
  • the said effluent evaporator (l ie) also collects contaminated effluent from primary gas cooler cum settling chambers (2), final gas cooler cum settling chambers (10), sets of gas condenser - 1 (5) and gas condenser -2 (6) and gas condenser -3 (7) and gas condenser -4 (8) in tar and tarry waste water storage tank (30) and feeds to the effluent evaporator (l ie) through effluent discharge pump (32).
  • the evaporated effluent is taken to nickel or tungsten wire mesh catalyst (1 1c) at the rotary kiln exit section (l id) and the cracked tar is partially steam reformed to get a minor amount of activated carbon which is another useful product of present invention.
  • the mixture of cracked tar gas with evaporated effluent is sucked by sealed blower (23) and refired back in the oxidation zone (lg) of gasifier (1) through refifing system (If) through water cooled nozzles (lg) in Gasifier (i). This refiring improves oxidation zone temperature and thereby helps in generation of better quality gas. Further, due to this refiring of cracked tar gas and evaporated effluent, there is no discharge of tar or contaminated effluent water to the atmosphere.
  • the water requirement of the present gasification system (100) is met through overhead water supply tank (14) whose level is maintained by an auto operated overhead water supply pump (16).
  • SCADA Supervisory Control and Data Acquisition System
  • SCADA Supervisory Control and Data Acquisition System
  • the present invention is a "Zero effluent Discharge Biomass Gasification System” which handles any solid biomass such as wood, peat, shells, lignite, coal, coke and offer dry, clean producer gas which can be used in any furnace, boiler ceramic kiln and combustion chamber of any system for clean combustion.

Abstract

Zero effluent discharge biomass gasification system (100) to facilitate no effluent discharge to the environment mainly comprises of gasifier (1); double lock hopper feeding system comprises of coal charger (20) comprising of coal feeding system (19) and coal feeding hopper (21); water sealed controlled gas shut off valve (25); primary gas cooler cum settling chamber (2); tar catcher (3); two way water seal controlled valve-1 (4); indirectly cooled final gas cooler cum settling chamber (10); sets of gas condenser-1 (5) and gas condenser-2 (6) and gas condenser-3 (7) and gas condenser-4 (8); through two-way water sealed controlled valve-2 (9) chilled water from water chilling plant (13); settling chamber (10); a rotary kiln cum effluent evaporator (11); tar and tarry waste water storage tank (30); high pressure tar pump (18); a burner (11a); producer gas supply pipe to the tar cracker (29); producer gas supply pipe to plant (31); rotary kiln (11b); Nickel or Tungston wire mesh catalyst (11c); kiln exit section (11d); effluent evaporator (11e) and sealed blower (23)

Description

Description
ZERO EFFLUENT DISCHARGE BIOMASS GASIFICATION
FIELD OF INVENTION
The present invention relates to the gasification system for any biomass such as wood, peat, shells, lignite, coal, coke etc. In particular the present invention relates to zero effluent discharge biomass gasification system which facilitates no effluent discharge to the environment.
BACKGROUND OF INVENTION
In biomass gasifier, the producer gas is produced. This gas contains moisture tar and particulates. Further, this gas leaks through series of connections and creates atmospheric pollution. The tar and particulates are usually removed through wet scrubbers and various filters. This produces contaminated effluent and filters which are finally discharged to the environment and creates environmental pollution.
There are different gasifier systems available in the market and there are various patents granted to different gasifiers but they have several disadvantages as compared to the proposed invention. A few patents disclosing such subject matter are described below:
Indian patent as per specification No. 92840 dtd.18th March 1964 (accepted on 12th August, 1965) deals with improvements relating to the gasification of finely divided solid fuels in suspension with oxygen or oxygen enriched air and if desired, water vapour. The invention is applicable to such process when carried out at high pressure. Indian patent as per specification No. 80239, 15th January 1962 (Accepted 4th April 1963) deals with Method and apparatus for the gasification of solid fuels. This invention relates to the gasification of solid fuels by means of preheated oxygen or oxygen enriched air and steam in rotary grate gasifier.
Indian Patent as per specification No. 86996 filed on 16th March 1963, Reciprocity date (United Kingdom) 21st March 1962 (Accepted 30th July 1964) deals with Improvements in Gasifiers. This invention relates to the production of gas in continuously slagging fixed bed gasifiers using solid fuels such as coal, coke, lignite and similar materials. The object of invention is to prevent, in a more efficient manner not only the clogging of the slag outlet from the hearth of a gasifier, but considerably to reduce the passage of solid fuel through this outlet. The invention is basically applied to slagging gasifier.
Indian Patent specification No. 162145 dtd. 22nd February 1984 accepted on 9th April 1988 deals with Process for producing refractory bricks for lining of smalter coal gasifier for production of reducing gas for producing pig iron characterized in that the part of gasifiers "attacked by liquid slags" having a molar ratio of CaO/Si02 below 2 is lined with unburned carbonallors magnesia bricks produced by mixing of fused magnesia with sinter magnesia.
US Patent No. US 6,439135 Bl dated August 27, 2002, deals with Organic Waste Gasification Processing and the production of alternative energy sources. This invention relates to the organic waste gasification processing using an Oxygen-starved (02-Starved) gasification process, and is also directed towards deriving alternative energy sources from by products produced by such a process. It is basically a municipal waste gasification system comprising of plurality of primary gasification chambers for receiving municipal waste and operating one or more chambers to produce an effluent by an oxygen straved process in primary and secondary combustion chambers.
US state patent No. US 8,252,072B2 dtd. August 18, 2012 deals with a downdraft -updraft gasifier and method for the gasification of biomass and waste to produce combustible effluent, a novel gasification system and method incorporating the gasifier and a novel filter to produce tar and moisture free producer gas and a novel polymer for use in gasifier. The present inventors have discovered that a gasifier having two oxidation zones, wherein in a first zone the gas flow is in a downward direction (in the same direction as the fuel flow) and in a second zone beneath the first zone the gas flow is upward (in the opposite direction to the fuel flow) addresses many of the operating difficulties in the known gasifiers. Such a device may be called a "down-updraft gasifier" to reflect the combination of the down and up flow of the gas.
The above mentioned patents are mostly related to gasifiers, its improvements and few novelty filters and methods of operating gasifiers. But they fail to provide clean, dry gas with zero effluent discharge to the environment.
In order to obviate the problems with prior art there is an unmeet need for a gasifier machine which offers better quality clean, dry gas with zero effluent discharge to the environment.
OBJECTS OF INVENTION The main object of the present invention is to provide zero effluent discharge biomass gasification system which produce better quality, dry and clean producer gas from any biomass such as wood, peat, shells, lignite, coal, coke etc. through refiring of cracked tar gas and evapdfated effluent in oxidation zone of gasifier and thus offer zero effluent discharge gasification system.
Another object of the present invention is to provide zero effluent discharge biomass gasification system which facilitates a tar cracker cum effluent evaporator for zero effluent discharge and to refire this cracked tar gas and evaporated effluent into oxidation zone of gasifier to improve its performance and achieve truly zero effluent discharge.
Yet another object of the present invention is to provide zero effluent discharge biomass gasification system which facilitates indirectly cooled primary gas cooler cum settling chamber at exit of gasifier and final exit of the system to cool and produce dry and particulate and tar free producer gas to be used in any furnace, kiln, boiler or combustion chamber.
Yet another object of the present invention is to provide zero effluent discharge biomass gasification system which incorporate wet electrostatic precipitator (tar catcher) to remove the tar from the producer gas.
Yet another object of the present invention is to provide zero effluent discharge biomass gasification system which facilitates a two way water-seal controlled valve to offer zero gas leakage system and provide for ease of maintenance and operation. Yet another object of present invention is to provide zero effluent discharge biomass gasification system which facilitates indirectly cooled set of condensers to condense any residual tar and water vapour from the producer gas.
Yet another object of present invention is to provide zero effluent discharge biomass gasification system which offer 100% indirect cooling for primary gas cooler-cum settling chambers at exit of gasifier, set of condensers and final gas cooler cum settling chamber at exit of whole gasification system to avoid any water contamination.
Yet another object of present invention is to provide zero effluent discharge biomass gasification system which produces a very small amount of activated carbon through steam reformation of tar in presence of Nickel / Tungston wire mesh as catalyst at exit section of tar cracker cum effluent evaporator.
BRIEF DESCRIPTION OF DRAWINGS:
Fig.1 : Shows perspective view of the present invention
Fig.2 : Shows enlarged front view of the present invention
Fig.3 : Shows back view of the present invention
Fig.4 : Shows top view of the present invention
Fig.5 : Shows left hand side view of the present invention
Fig.6 : Shows the cross- section view of gasifier
Fig.7 : Shows the cross-section view of primary gas cooler cum settling chamber and indirectly cooled final gas cooler cum settling chamber
Fig.8 : Shows the back view of two way water seal controlled valve A - 1 and two way water seal controlled valve - 2
: Shows the front view of two way water seal controlled valve B - 1 and two way water seal controlled valve - 2
: Shows the side view of two way water seal controlled valve C - 1 and two way water seal controlled valve - 2
Fig.9 : Shows the front view of rotary tar kiln cum effluent A evaporator
: Shows the left view of rotary tar kiln cum effluent B evaporator
: Shows the top view of rotary tar kiln cum effluent C evaporator
Meaning of reference numerals Used in the figures 1 to 9:
100 Gasification system
1 Gasifier
la Air supply line
lb Water jacket
lc Supply line
Id Rotating grate
le Water seal
If Refiring system
ig Oxidation zone
2 Primary gas cooler cum settling chamber
2a Upper metallic hopper
2b Lower metallic hopper
2c Inlet water supply header
2d Outlet water header e Series of cooling coils f Gas inlet
g Gas outlet
Tar catcher
Two way water seal controlled valve - 1
Gas condenser - 1
Gas condenser - 2
Gas condenser - 3
Gas condenser - 4
Two way water seal controlled valve - 2
10 Final gas cooler cum settling chamber
1 1 Rotary tar kiln cum effluent evaporator
1 1a Burner
l ib Rotary kiln
11c Nickel or tungston wire mesh
l id Kiln exit section
l ie Effluent evaporator
12 Induced draught air cooling tower
13 Water chilling plant
14 Overhead water supply tank
15 Hot air centrifugal blower
16 Overhead water supply pump
17 Cooling water pump
18 High pressure tar pump
19 Coal feeding system
0 Coal charger
0a Water seal for coal charger
1 Coal feeding hopper
1a - Water seal for coal feeding hopper 2 Twin lobe blower
3 Sealed blower 24 : SCADA system (Supervisory Control and Data Acquisition
System)
25 : Water seal controlled gas shut off valve
26 : Structure
27 : Tar cracker ID fan
28 : Air supply blower for tar cracker
29 : Producer gas supply pipe to tar cracker
30 : Tar and tarry waste water storage tank
31 : Producer gas supply pipe to plant
32 : Effluent discharge pump
33 : Water tank- 1
34 : Water tank- 2
DETAILED DESCRIPTION OF INVENTION:
The features, nature and advantages of the disclosed subject matter will become more apparent from the detailed description set forth below when taken in conjunction with the drawings in which like reference numerals identify correspondingly throughout.
As shown in fig.1 to fig.5, the present invention relates to Zero effluent discharge biomass gasification system (100).
This is a unique feature of this gasification system which helps in improving combustion zone temperature which ultimately helps in generating better quality producer gas.
Referring to fig.6, the present invention gasification system (100) is provided with gasifier (1) for producing the producer gas which is supported by a steel structure (26). The gasifier (1) comprises of a shell which is immersed in water seal (le) which prevents air ingress to the gasifier (1) as well as avoids gas leakage to the atmosphere. The gasifier (1) further comprises of top which is connected with double lock hopper system for feeding biomass. The said double lock hopper feeding system which is fixed at the top of the gasifier (1) to feed the biomass is comprised of coal charger (20) and coal feeding hopper (21) which facilitates gas leak proof feeding to the gasifier ( 1). The said coal charger (20) receives the biomass from coal feeding system (19). The bottom of the said coal charger (20) is water sealed by water seal for coal charger (20a). The biomass from the coal charger (20) delivers to coal feeding hopper (21) when the said coal feeding hopper (21) is empty. The coal feeding hopper (21) supplies biomass to the gasifier (1) as per the requirements. The bottom of this coal feeding hopper (21) is also water sealed by water seal for coal feeding hopper (21a). Hence the double lock coal feeding system (19) facilitates the feeding of biomass to the gasifier (1) without any gas leakage. Furthermore, the gasifier (1) comprises of water jacket (lb) for receiving hot air supply from the hot air centrifugal blower (15) through air supply line (la). The mixture of steam and air at about 60°C to 70°C from top side is fed through supply line (lc) below rotating grate (Id). A twin lobe blower (22) is incorporated at the gasifier (1) for supplying high pressure air in case of chocking of gasifier (1). Moreover, the gasifier (1) comprises of oxidation zone (lg) for refiring evaporated effluent and cracked tar from rotary tar kiln cum effluent evaporator (1 1) through refiring system (If). The said refiring system (If) is used for refiring of cracked tar and evaporated effluent effectively in the oxidation zone (lg) of gasifier (1) which helps in improving the efficiency of gasifier (1)·
The producer gas generated in gasifier (1) goes to water sealed controlled gas shut off valve (25) which regulates or shut off the producer gas supply to the primary gas cooler cum settling chamber (2). This producer gas has a high exit temperature, tar content and particulate matters. This producer gas is indirectly cooled in this primary settling chamber cum gas cooler (2).
Referring to fig.7, the present invention gasification system (100) is provided with indirectly cooled primary gas cooler cum settling chamber (2) which is attached after water seal controlled gas shut off valve (25) for receiving the hot producer gas from the gasifier (1), cooling the producer gas, settling down the particulates present in producer gas and furt er passing the relatively clean and cooled producer gas to tar catcher (3). The said primary gas cooler cum settling chamber (2) is comprised of gas inlet (2f) for receiving the hot producer gas from the gasifier (1), upper metallic hopper (2a) to reduce the gas velocity for facilitating the settling of particles, series of cooling coils (2e) for cooling the producer gas, lower metallic hopper (2b) which acts as water seal cum particle collector, inlet water supply header (2c) to supply water to the series of cooling coils (2e), outlet water header (2d) to collect the hot water from the series of cooling coils (2e) and gas outlet (2g) for passing the relatively clean and cooled producer gas to tar catcher (3).
Referring to fig.1 to fig.5, tar catcher (3) is provided for receiving relatively clean and cool gas from primary gas cooler cum settling chamber (2) for isolating the tar present in producer gas at bottom of tar catcher (3) as liquid tar. The tar catcher (3) comprises of series of electrodes maintained at high potentials. The tar gets migrated to the electrodes due to high potential and flows down as liquid tar and deposited at the bottom.
Referring to fig.8, two way water seal controlled valve- 1 (4) is provided for receiving relatively clean particulate and tar free producer gas from tar catcher (3) and direct the said producer gas to any one set of the gas condenser - 1 (5) and gas condenser -2 (6) or gas condenser -3 (7) and gas condenser -4 (8) depending on the availability. This provides ease of operation and maintenance without any gas leakage to the atmosphere avoiding the atmospheric pollution. The said two way water seal controlled valve- 1 (4) mainly comprises of one gas inlet for receiving relatively clean particulate and tar free producer gas from tar catcher (3), water storage tank for storing water, upper water tank-2 (34) to control water level to supply gas in one of gas outlet, lower water tank - 1 (33) to control water level to supply gas in another gas outlet depending on requirements. The pair of gas outlets direct the producer gas to respective set of gas condenser - 1 (5) and gas condenser -2 (6) and gas condenser -3 (7) and gas condenser -4 (8) depending on requirement. By controlling water level in either of lower water tank- 1 (33) or upper water tank- 2 (34), the producer gas is directed to any one of the pair of gas outlet and thus provides flexibility of operation.
Referring to fig.1 to fig.5, sets of gas condenser - 1 (5) and gas condenser -2 (6) and gas condenser -3 (7) and gas condenser -4 (8) are provided in parallel, with each set containing two condensers in series. The s.aid sets of gas condenser - 1 (5) and gas condenser -2 (6) and gas condenser -3 (7) and gas condenser -4 (8) in parallel, with each set containing two condensers in series to condense the water vapour in relatively clean and tar free producer gas coming from tar catcher (3). The said both set of gas condenser - 1 (5) and gas condenser -2 (6) and gas condenser -3 (7) and gas condenser -4 (8) in series are indirectly cooled through water circulated from cooling water pump (17) incorporated at induced draught air cooling tower (12) and thus, avoiding water contamination. The condensed water which contains minor traces of tar also is collected in the bottom of each set of gas condenser - 1 (5) and gas condenser -2 (6) and gas condenser -3 (7) and gas condenser -4 (8). The bottom and lids of both sets of gas condenser - 1 (5) and gas condenser -2 (6) and gas condenser -3 (7) and gas condenser -4 (8) are water sealed thus preventing both gas leakage and effluent leakage through each set of gas condenser - 1 (5) and gas condenser -2 (6) and gas condenser -3 (7) and gas condenser - 4 (8) facilitating zero discharge of effluent or gas to the atmosphere.
Referring to fig.7, indirectly cooled final gas cooler cum settling chamber ( 10) is provided for receiving producer gas from any of the sets of gas condenser - 1 (5) and gas condenser -2 (6) or gas condenser -3 (7) and gas condenser -4 (8) through two-way water sealed controlled valve-2 (9). The chilled water from water chilling plant (13) circulates through cooling coils in settling chamber (10) for indirectly cooling the producer gas below atmospheric temperature. This sub- cooling of producer gas makes the said producer gas a dry gas and residual water vapour along with tar gets condensed which is collected at the bottom of indirectly cooled final gas cooler cum settling chamber
( 10) . Further, also the fine particles get settled in indirectly cooled final gas cooler cum settling chamber (10) leaving a clean, extremely dry and tar free producer gas at the exit indirectly cooled final gas cooler cum settling chamber (10) for use in any furnace, in engine or ceramic kiln or combustion chamber.
Referring to fig.9, a rotary tar kiln cum effluent evaporator (11) is provided for receiving a liquid tar which is collected in tar and tarry waste water storage tank (30) from the bottom of tar catcher (3). High pressure tar pump (18) supplies the liquid tar from tar and tarry waste water storage tank (30) to the rotary tar kiln cum effluent evaporator
(11) . The said liquid tar impinges on the rotating red hot surface of kiln which is heated externally. A burner (1 1a) is embodied in kiln which fires producer gas supplied from producer gas supply pipe to the tar cracker (29) which receives producer gas from producer gas supply pipe to the plant (31) and heats the tar cracker cum rotary kiln (l ib). The air required to fire the producer gas in the burner (11a) in the rotary kiln (11) is supplied through a separate air supply blower for tar cracker (28). The temperature of the rotary kiln (l ib) is maintained at 400°C to 500°C. Due to the high temperature the said tar gets cracked. The cracked tar gas is taken into Nickel or Tungsto wire mesh catalyst (11c) incorporated at the kiln exit section (l id). The cracked tar gas is fed to Nickel or Tungston wire mesh catalyst (1 1c) and exit of kiln (l id) where tar gets partially steam reformed to activated carbon, which is a valuable product.
The effluent evaporator (l ie) is integrated with the rotary kiln cum effluent evaporator (1 1) for receiving hot flue gases and for finally discharging to the atmosphere through an ID fan (27). The said effluent evaporator (l ie) also collects contaminated effluent from primary gas cooler cum settling chambers (2), final gas cooler cum settling chambers (10), sets of gas condenser - 1 (5) and gas condenser -2 (6) and gas condenser -3 (7) and gas condenser -4 (8) in tar and tarry waste water storage tank (30) and feeds to the effluent evaporator (l ie) through effluent discharge pump (32). The evaporated effluent is taken to nickel or tungsten wire mesh catalyst (1 1c) at the rotary kiln exit section (l id) and the cracked tar is partially steam reformed to get a minor amount of activated carbon which is another useful product of present invention. The mixture of cracked tar gas with evaporated effluent is sucked by sealed blower (23) and refired back in the oxidation zone (lg) of gasifier (1) through refifing system (If) through water cooled nozzles (lg) in Gasifier (i). This refiring improves oxidation zone temperature and thereby helps in generation of better quality gas. Further, due to this refiring of cracked tar gas and evaporated effluent, there is no discharge of tar or contaminated effluent water to the atmosphere.
The water requirement of the present gasification system (100) is met through overhead water supply tank (14) whose level is maintained by an auto operated overhead water supply pump (16).
Further, the operation of entire system is monitored, recorded and controlled by specifically developed instrumentation and programming through SCADA (Supervisory Control and Data Acquisition System) based online system (24). The said SCADA (Supervisory Control and Data Acquisition System) based online system (24) enables online as well as remote · sensing through internet connectivity with static IP, operating, recording and controlling of entire gasification system.
Thus, the present invention is a "Zero effluent Discharge Biomass Gasification System" which handles any solid biomass such as wood, peat, shells, lignite, coal, coke and offer dry, clean producer gas which can be used in any furnace, boiler ceramic kiln and combustion chamber of any system for clean combustion.

Claims

Zero effluent discharge biomass gasification system (100) mainly comprises of: gasifier (1) for producing the producer gas further comprises of a shell which is immersed in water seal (le) which prevents air ingress to the gasifier (1) as well as avoids gas leakage to the atmosphere, top which is connected with double lock hopper feeding system for feeding biomass, water jacket (lb) for receiving hot air supply from the hot air centrifugal blower (15) through air supply line (la) and further feeding the mixture of steam and air at about 60°C to 70°C from top side through supply line (lc) below rotating grate (Id), a twin lobe blower (22) which is incorporated at the gasifier (1) for supplying high pressure air in case of chocking of gasifier (1), oxidation zone (lg) for refiring evaporated effluent and cracked tar from rotary tar kiln cum effluent evaporator (11) through refiring system (If) which is used for refiring of cracked tar and evaporated effluent effectively in the oxidation zone (lg) of gasifier (1) which helps in improving the efficiency of gasifier (1); double lock hopper feeding system which is fixed at the top of the gasifier ( 1) comprises of coal charger (20) for receiving the biomass from coal feeding system (19) and. delivering to coal feeding hopper (21) when the said coal feeding hopper (21) is empty and coal feeding hopper (21) supplies biomass to the gasifier (1) as per the requirement whereby the bottom of the said coal charger (20) and coal feeding hopper (21) are water sealed, respectively, by water seal for coal charger (20a) and water seal for coal feeding hopper (21a) to facilitate gas leak proof feeding of the biomass to the gasifier (1); water sealed controlled gas shut off valve (25) to receive the producer gas generated in gasifier (1) and further supply to the primary gas cooler cum settling chamber (2) for cooling as the said producer gas has a high exit temperature, tar content and particulate matters; primary gas cooler cum settling chamber (2) which is attached after water seal controlled gas shut off valve (25) for receiving the hot producer gas from the gasifier (1), cooling the producer gas, settling down the particulates present in producer gas and further passing the relatively clean and cooled producer gas to tar catcher (3) whereby the said primary gas cooler cum settling chamber (2) is comprised of gas inlet (2f) for receiving the hot producer gas from the gasifier (1), upper metallic hopper (2a) to reduce the gas velocity for facilitating the settling of particles, series of cooling coils (2e) for cooling the producer gas, lower metallic hopper (2b) which acts as water seal cum particle collector, inlet water supply header (2c) to supply water to the series of cooling coils (2e), outlet water header (2d) to collect the hot water from the series of cooling coils (2e) and gas outlet (2g) for passing the relatively clean and cooled producer gas to tar catcher (3); tar catcher (3) for receiving relatively clean and cool gas from primary gas cooler cum settling chamber (2) and for isolating the tar present in producer gas at bottom of tar catcher (3) as liquid whereby tar catcher (3) comprises of series of electrodes maintained at high potentials whereby the tar gets migrated to the electrodes due to high potential and flows down as liquid tar and deposited at the bottom; two way water seal controlled valve- 1 (4) for receiving relatively clean particulate and tar free producer gas and direct the said producer gas to any one set of the gas condenser - 1 (5) and gas condenser -2 (6) or gas condenser -3 (7) and gas condenser -4 (8) depending on the availability which would ease the operation and maintenance without any gas leakage to the atmosphere avoiding the atmospheric pollution whereby the said two way water seal controlled valve- 1 (4) mainly comprises of one gas inlet for receiving relatively clean particulate and tar free producer gas from tar catcher (3), water storage tank for storing water, upper water tank-2 (34) to control water level to supply gas in one of gas outlet, lower water tank - 1 (33) to control water level to supply gas in another gas outlet depending on requirements and a pair of gas outlets for directing the producer gas to respective set of gas condenser - 1 (5) and gas condenser - 2 (6) or gas condenser -3 (7) and gas condenser -4 (8) depending on requirement; sets of gas condenser - 1 (5) and gas condenser -2 (6) and gas condenser -3 (7) and gas condenser -4 (8) in parallel, with each set containing two condensers in series to condense the water vapour in relatively clean and tar free producer gas coming from tar catcher (3) whereby both set of gas condenser - 1 (5) and gas condenser -2 (6) and gas condenser -3 (7) and gas condenser -4 (8) in series are indirectly cooled through water circulated from cooling water pump (17) incorporated at induced draught air cooling tower (12) and thus, avoiding water contamination and the condensed water which contains minor traces of tar also is collected in the bottom of each set of gas condenser - 1 (5) and gas condenser -2 (6) and gas condenser -3 (7) and gas condenser -4 (8) whereby the bottom and lids of both sets of gas condenser - 1 (5) and gas condenser -2 (6) and gas condenser -3 (7) and gas condenser -4 (8) are water sealed thus preventing both gas leakage and effluent leakage through each set of gas condenser -
1 (5) and gas condenser -2 (6) and gas condenser -3 (7) and gas condenser -4 (8) facilitating zero discharge of effluent or gas to the atmosphere; indirectly cooled final gas cooler cum settling chamber (10) for receiving producer gas from any of the sets of gas condenser - 1 (5) and gas condenser -2 (6) and gas condenser -3 (7) and gas condenser -4 (8) through two-way water sealed controlled valve-
2 (9) and the chilled water from water chilling plant (13) circulates through cooling coils in settling chamber (10) for indirectly cooling the producer gas below atmospheric temperature where the sub-cooling of producer gas makes the said producer gas a dry gas and residual water vapour along with tar gets condensed which is collected at the bottom of indirectly cooled final gas cooler cum settling chamber (10) and also the fine particles get settled in indirectly cooled final gas cooler cum settling chamber (10) leaving a clean, extremely dry and tar free producer gas at the exit of indirectly cooled final gas cooler cum settling chamber (10) for use in any furnace, in engine or ceramic kiln or combustion chamber; a rotary kiln cum effluent evaporator (1 1) for receiving a liquid tar which is collected in tar and tarry waste water storage tank (30) from the bottom of tar catcher (3) through a high pressure tar pump (18) and the said liquid tar is impinged on the rotating red hot surface of kiln which is heated externally by a burner ( 1 1a) embodied in kiln which fires producer gas supplied by producer gas supply pipe to the tar cracker (29) which receives producer gas from producer gas supply pipe to the plant (31) and heats the tar cracker cum rotary kiln (l ib), whereby the temperature of the rotary kiln (l ib) is maintained at 400°C to 500°C due to the high temperature the said tar gets cracked and the cracked tar gas is taken into Nickel or Tungston wire mesh catalyst (1 lc) incorporated at the kiln exit section (l id) where tar gets partially steam reformed to activated carbon; effluent evaporator (l ie) which is integrated with the rotary kiln cum effluent evaporator (1 1) for
receiving hot flue gases and finally discharged to the atmosphere through an ID fan (27) and
for collecting the contaminated effluent from primary gas cooler cum settling chambers (2), final gas cooler cum settling chambers (10), sets of gas condenser -1 (5) and gas condenser -2 (6) and gas condenser -3* (7) and gas condenser -4 (8) in tar and tarry waste water storage tank (30) and feeding to the effluent evaporator (He) through effluent discharge pump (32) for effluent evaporation and the said evaporated effluent is then taken on Nickel or Tungston wire mesh catalyst (11c) incorporated at the kiln exit section (l id) where the cracked tar gets partially steam reformed to get a minor amount of activated carbon and sealed blower (23) for sucking the mixture of cracked tar gas with evaporated effluent and passing to the oxidation zone (lg) of gasifier (1) for refiring back through refiring system (If) whereby the said refiring improves oxidation zone temperature thus, helps in generation of better qualit gas and further, due to the refiring of cracked tar gas and evaporated effluent, there is no discharge of tar or contaminated effluent water to the atmosphere.
Zero effluent discharge biomass gasification system (100) as claimed in claim 1, whereby controlling water level in either of lower water tank- 1 (33) or upper water tank- 2 (34), the producer gas is directed to any one of the pair of gas outlet and thus provides flexibility of operation.
Zero effluent discharge biomass gasification system (100) as claimed in claim 1 , whereby the air required to fire the producer gas in the burner (1 1a) in the rotary kiln (1 1) is supplied through a separate air supply blower for tar cracker (28).
Zero effluent discharge biomass gasification system (100) as claimed in claim 1, whereby the water requirement of the present gasification system (100) is met through overhead water supply tank (14) whose level is maintained by an auto operated overhead water supply pump (16).
Zero effluent discharge biomass gasification system (100) as claimed in claim 1, whereby the operation of entire system is monitored, recorded and controlled by specifically developed instrumentation and programming through SCADA (Supervisory Control and Data Acquisition System) based online system (24). The said SCADA (Supervisory Control and Data Acquisition System) based online system (24) enables online as well as remote sensing through internet connectivity with static IP, operating, recording and controlling of entire gasification system.
Zero effluent discharge biomass gasification system (100) as claimed in claim 1, which uses any solid biomass such as wood, peat, shells, lignite, coal, coke as raw material and produce dry, clea producer gas which can be used in any furnace, boiler ceramic kiln and combustion chamber of any system for clean1 combustion.
PCT/IN2013/000707 2013-06-26 2013-11-21 Zero effluent discharge biomass gasification WO2014207755A1 (en)

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