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Abstract Godfrey Iii, Edward Eugene ABSTRACT GODFREY III, EDWARD EUGENE. Gas-Insulated Gasifier for Biomass Derived Producer Gas. (Under the direction of Dr. Mari S. Chinn). This work focused on designing and fabricating a novel downdraft gasifier for biomass derived producer gas. Biomass offers itself up as a viable alternative energy source that can be sustained anywhere that agricultural and forestry commodities are grown. Gasification technology provides a means to manage and add value to normally underutilized agricultural and forestry crops and residues. Gasification can produce energy-rich gases while consuming fuel sources high in lignocellulose, offering an advantage over other bio-energy generation methods that cannot effectively use or convert lignin and hemicellulose. The objectives of this project were to 1) examine and describe the theory behind downdraft gasification; 2) design and fabricate a novel downdraft gasifier capable of generating producer gas from readily available fuels; and 3) investigate the effects of solid fuel physical characteristics (charcoal and sweet sorghum) and gasifying agent (air) flow rates 25.48 m3 h-1 (15 ft3 min-1) and 50.97 m3 h-1 (30 ft3 min-1) on gasification effectiveness. A research scale gas-insulated downdraft gasifier was designed using figures derived from published data in the field of biomass gasification. Design criteria for the gasifier included research-scale (e.g. quick run time and change over between testing events), mobility, modularity, gas conditioning (e.g. cooling and cleaning), and data acquisition with automated control capabilities. The gasifier was assembled from four major components (e.g. inner chamber, superstructure, outer panels, and ash collection), and mounted on caster wheels for mobility. The gasifier was one component of a greater gasification system that included cyclone filtration and a counter flow heat exchanger. Gasification runs on charcoal and chopped sweet sorghum at the two flow rates were completed at random and producer gas samples were collected twice during each run. Sample gas composition was determined for H2, N2, CO, CH4 and CO2 by gas chromatography. Temperature data was collected and recorded using thermocouples and a programmable logic controller. The effects of gasifying agent flow rate and fuel physical characteristics on producer gas composition, maximum gasifier zone temperature and solid fuel consumption rate were directly measured or calculated. Gaseous fuel from field chopped sorghum on average 3 contained 5.3% (by vol.) less H2 and 14.0% (by vol.) less CO than charcoal runs at 25.48 m -1 3 -1 h . Charcoal runs at 50.97 m h contained 2.9% (by vol.) more H2 and 9.9% (vol.) more CO than charcoal at 25.48 m3 h-1. On average, at higher air flow rates charcoal was consumed 3.84 kg h-1 faster than at low flow rates. At the high flow rate sorghum burned 2.95 kg h-1 slower than charcoal. Maximum reduction zone temperatures on charcoal and sorghum at 50.97 m 3 h-1 were 62.82 and 39.39 °C greater, respectively than at 25.48 m3 h-1. © Copyright 2012 by Edward Eugene Godfrey III All Rights Reserved Gas-Insulated Gasifier for Biomass Derived Producer Gas by Edward Eugene Godfrey III A thesis submitted to the Graduate Faculty of North Carolina State University in partial fulfillment of the requirements for the Degree of Master of Science Biological and Agricultural Engineering Raleigh, North Carolina 2012 APPROVED BY: _______________________________ ______________________________ Larry F. Stikeleather Matthew W. Veal ________________________________ Mari S. Chinn Committee Chair DEDICATION I dedicate this to my family and friends because without them I would not be where I am today. ii BIOGRAPHY Edward Eugene Godfrey III was born on November, 13, 1986 in Norfolk, Virginia. He is the first born of Edward (Gene) E. Godfrey, Jr., and Suzanne Haskell and older brother to Randall and Jennifer Godfrey. Edward was raised in Moyock, North Carolina by his Dads side spending many days in the field and countless hours on farm equipment. His time spent working the land and on equipment showed him the pains and joys of agricultural life. This passion for machines and agriculture led him to NC STATE to try to make farming better for everyone engaged in feeding the world. Edward graduated from Currituck County High School in 2005 shortly after applying to North Carolina State University. Long before even applying to college he knew what he wanted to do and it was to be an Agricultural Engineer. After being accepted there was no question that Biological and Agricultural Engineering was the degree of choice. In 2007 he met Dr. Mari Chinn, and in 2009 she offered him a position working with her on a gasification project. In 2010 after spending five years getting a four year degree, Edward graduated with a Bachelor of Science in Biological and Agricultural Engineering and felt it was only natural to extend his stay in Weaver labs for at least two more years and get a Master of Science degree. In the fall of 2010, he continued research on designing and testing a novel gasification system as a graduate student under the direction of Dr. Chinn. Edward "wasn't much on the thought of a coat and tie" but he would put one on for a special occasion. Some say he would "come off a little rough sometimes". "But folks who knew him knew that if you look past a dirty shirt and see beyond greasy hands you would find heart hard at work in a darn good man." Edward has been blessed with a great family iii and great friends while he pursued a life at North Carolina State University and if he could he would remind you that it's the neighbor you are, not the neighborhood you are in. iv ACKNOWLEDGMENTS I want to acknowledge my Dad, Mom, Brother and Sister for all of their support and wisdom. I would also like the acknowledge Dr. Chinn for the opportunity she has given me to work with her on this project. v TABLE OF CONTENTS LIST OF TABLES ............................................................................................................. ix LIST OF FIGURES .............................................................................................................x CHAPTER 1: Biomass Gasification- A literature review ....................................................1 1.1 Introduction ....................................................................................................................1 1.2 History of Gasification ...................................................................................................1 1.3 Biomass as a Fuel...........................................................................................................3 1.4 Gasification Processes ...................................................................................................5 1.4.1 Overview ...................................................................................................5 1.4.2 Reaction Zones..........................................................................................6 1.4.2.1 Drying and Storage ..............................................................6 1.4.2.2 Pyrolysis ...............................................................................6 1.4.2.3 Combustion/Oxidation .........................................................6 1.4.2.4 Reduction .............................................................................8 1.5 Gasifier Technology.......................................................................................................9 1.5.1 Fixed Bed ..................................................................................................9 1.5.1.1 Updraft ...............................................................................10 1.5.1.2 Crossdraft ...........................................................................11 1.5.1.3 Downdraft ..........................................................................12 1.5.2 Fluidized Bed ..........................................................................................13 1.6 Producer Gas Uses .......................................................................................................14 1.7 Objectives ....................................................................................................................15 1.8 References ....................................................................................................................17 CHAPTER 2: Theory of Downdraft Gasification...............................................................19 2.1 Introduction ..................................................................................................................19 2.2 The Downdraft Concept ...............................................................................................20 2.2.1 Principles.................................................................................................20 2.3 Gasification Thermochemistry .....................................................................................21 2.3.1 Combustion .............................................................................................22 2.3.2 Drying & Storage ....................................................................................23 2.3.3 Pyrolysis ..................................................................................................23 2.3.4 Reduction ................................................................................................24 2.3.5 Gasifying Agent Delivery Requirements ................................................26
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