gasification Biomass Gasification Power and heat generation
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1 Gasification Biomass gasification Power and heat generation
2 Company profile GB Consulting s.r.o. together with IE India Pvt. Ltd. is a famous leader in conversion of biomass into electrical and thermal energy and biomass technologies in global market. As a technology focused company has IE India Pvt. Ltd. two decades of experience with solutions for using biomass for energy production. In 2012 the company IE India Pvt. Ltd. signed a technological partnership with GB Gasifired Europe to improve biomass gasification technology. GB Gasifired Europe provides development and research gasification technology, the manufacturing and sale of technologies for the European and American markets. Over the years, the company IE India Pvt. Ltd. has established good name in the uses of biomass, designed and developed its own original variety of systems for biomass gasification, pyrolysis of biomass, biomass briquetting and drying of biomass. Infrastructure & Manpower The company is in Faridabad, Haryana state, one of well-known industrial centers of India. The factory has all facilities, machinery and equipment required for the manufacturing, installation and testing of all products in our manufacturing range. The benefit of the company is very good personal cast, including managers, engineers and experienced technicians. Our working philosophy is quality at every step for a quality of each product. The workforce has a very high quality level and this fact guarantees timely delivery time and quality of product. Quality (certified according to ISO 9001:2008) In the companies GB Consulting and IE India Pvt. Ltd. is quality a mantra. Management and all levels of staff have high knowledge and strong belief about the importance of quality. All processes in both companies are focusing on the most important target - to maintain high and constant quality standard. Efficiency is based on the ISO 9001:2008 certification, awarded by The United Kingdom Accreditation Service. GB Consulting Company owns European Certificate (CE mark) for all supplied Gasification technology. Our Strengths eing a company managed by technocrats, the emphasis is placed on technology and product development. The core strength of the company is design and application engineering. The company regularly comes out with innovative products and solutions. Some of our unique solutions are: Gasification Fully automatic burners Syn-Gas (hot & cold) Clean gas drying system (without the use of water and water purification) Automatic regulation of reactor Cooling and gas cleaning with zero waste Gasification units for different fuels Counter flow biomass gasification unit Universal gasification units Universal Gasifier for gasification of dust and powder biomass Gasification unit for briquettes and pellets from biomass Gasification units for soft biomass, garden waste, wood, straw, etc. Wood dryer dosage / continuous operation Cogeneration units provided for high electrical efficiency Customer Satisfaction GB Gasifired Europe and IE India Pvt. Ltd make an effort to involve and understand the customer s requirements and problems, to offer not only a superior product but also a most suitable business solution. The emphasis is on better interaction and understanding to build long term relationships. It is this commitment to the customer s business that drives our efforts towards creating advances in technology through innovation. Not for the sake of technology, but towards bettering our customer s business through productivity, profitability and peace-of-mind. Today we have more than 500 implementation with a history of more than 10 years.
3 Gasification units delivered by by GB Gasifired Europe The Gasifier unit is essentially a chemical reactor, where several thermo-chemical processes such as pyrolysis, combustion, and reduction take place. Most biomass materials like wood, charcoal, straw, grass and rice husk etc. can be converted into a gaseous fuel known as Syn-Gas, which comprises carbon monoxide, hydrogen, carbon dioxide, methane, and nitrogen. This gas has a lower calorific value ( kcal/nm 3 ) compared to natural gas or liquefied petroleum gas, but can be burnt directly with high efficiency and good degree of control without emitting smoke. The Syn-Gas flame temperature can be as high as 1100 C. Each kilogram of air-dry biomass (10% moisture content) yields about 2.5 nm 3 of Syn-Gas. In energy terms, the conversion efficiency of the gasification process is in the range of 80% 90%. Basic Features Typical payback is within < 48 months Fully Automatic Gasification system & Burners Very low maintenance, No operative risk, easy to operate Compact Foot Print Multi Fuel systems Dry Gas System Zero Tar/ Effluent system Highest Overall Efficiency Advantages of GB Gasifired Europe technology Gasifier Biomass Our technology gasifiers have range of special features that gives them a distinctive advantage in thermal applications. Dry gas system: We offer completely dry gas generators which do not require water/scrubber based gas cleaning. This not only improves the overall thermal efficiency, but also eliminates the problems with effluent treatment discharge. Hot gas filter: We have developed a unique gas filter that operates at temperatures up to 395 C and can trap very fine dust particles, resulting in a very clean hot gas. Compact footprint: The GB Gasifired - Vergassen series gasifiers are the most compact gasification systems available in India, the rest of Asian countries and now in Europe. The compact design not only requires a much smaller area for installation but also minimizes heat loss and increases overall thermal efficiency. Zero effluent system: The GB Gasifired - Vergassen series is designed to have minimum waste products and zero liquid effluents. Highest overall efficiency: The GB Gasifired - Vergassen systems are designed for maximum overall thermal efficiency. The conversion and overall thermal efficiency of the system are as high as 90%. design Kateřina Válková, ELVEKO CZ s. r. o., Advanced control and automatic: The GB Gasifired - Vergassen gasifiers are provided (optional) with a range of innovative control and automation features so the gas generation (and consequently fuel wood consumption) is automatically controlled to respond to the thermal load requirement. (PLC panel, remote control system all technology process). Fully automatic burners (optional): The production of good quality gas from wood is just half of the solution. The solution is complete only when an appropriately designed burner is used to burn the gas. We have indigenously developed a wide range of fully automatic burners for Syn-Gas from capacities from kcal/hr. to kcal/hr. These burners are loaded with all the safety features of conventional automatic burners. We offer single stage, double stage or continuously modulating type burners depending on the capacity and application.
4 Gasification units Downdraft In this type, air is brought into downward flowing fixed area or solid fuels and gas is drawn off to the bottom. A lower overall efficiency and difficulties in handling higher moisture are the limitations in downdraft gas producers. The time (5 10 minutes) needed to ignite and bring plant to working temperature with good gas quality is shorter than updraft gas producer. This gasifier is suitable for internal combustion engines after appropriate cleaning. These gasifiers are best suited for applications where clean fuel gas is required and where temperature control is critical. These gasifier can be used in applications requiring moderate temperatures up to 600 C. Typical applications where the down draft gasifiers have been successfully used are: Continuous baking ovens (bread, biscuits, paint) Batch type baking oven rotary oven for bread Dryers & Curing tea, coffee, mosquito coil, paper drying Boilers Thermic fluid heaters Annealing furnaces Direct fired rotary kilns Internal combustion Engines and CHP Air Wood Pyrolysis Combustion Reduction Air Gas Updraft Gasifier An updraft gasifier has clearly defined zones for partial combustion, reduction and pyrolysis. Air is introduced at the bottom and act as countercurrent fuel flow. The gas is drawn in higher location. The updraft gasifier achieves the highest efficiency as the hot gas passes through fuel bed and leaves the gasifier at low temperature. The sensible heat given by gas is used to preheat and dry fuel. These gasifiers are best suited for applications where moderate amounts of dust in the fuel gas are acceptable and a higher flame temperature is required. Fuel Typical applications where the updraft gasifiers have been successfully used are: Packaged boilers Thermic fluid heaters All kinds of fryers Rotary type roasters Aluminum melting /annealing furnace Drying Pyrolysis Reduction Combustion Syngas Air Universal gasification unit GB Gasifired Gasification units GB Gasifired are based on the principle of flow drift and are able to transform any biomass to Syn-Gas of high quality and with an insignificant proportion of tar. The only limitation of the gasification unit is the size of fuel < 3 mm. Universal gasification units are unique in their ability to gasify even a low quality fuels, such as soy beans, cereal straw and rapeseed, mustard stalks, sunflower hulls, oily skin, etc., containing a high proportion of ash and low quality flow. Technology and unique design of the reactor and effective drying system are the result of more than fifteen years of continuous development. Universal gasification unit is most useful for applications with medium to high requirements for electrical and thermal energy, usually from 70 kw to 3000 kw (electrical power).
5 Universal gasifier (UG) gasification unit Main characteristic of the technology: Flexibility of raw materials: suitable for almost all types of biomass (even in powder form) Incredibly small size of the construction area High carbon conversion efficiency > 91% Shorter start-up time High availability and low maintenance requirements Syn-Gas tar-free Dry gas cleaning All units - technology are made to order from 70 kw 3000 kw (electrical power). Gasifier Performance Range To our customers we offer gasifier units in the performance range from 80 kw up to applications with the performance in MW. Performance range Fuel consumption Power generation [kwe/h] [kg/hr] [t/day] [t/year] [MWh/year] , , , , , , , , , , , Number of operation hours [hrs/year]. With the biomass humidity about 15 %. Selection of a suitable input raw materialsy Different types of gasification units need different types of fuel to achieve the best possible efficiency. Examples of biomass type which gasification unit can use: Parallel flow gasification unit wood chips, briquettes, lump wood Countercurrent gasification unit wood chips, pellets, lump wood Twister-fluidized gasification unit stalk, straw, grass, sawdust, crushed waste from biomass
6 Advantage of GB Gasifired technology GB Gasifired systems have a number of unique features and it makes them an ideal solution for Industrial Heat & Power. Simple, Easy Operation, Easy to load, Simple to start All you ll need to start the GB Gasifired system is a fire lighter and some light sticks. The Gasifier manages the rest of the startup procedure making sure that the fire builds up as quickly and efficiently as possible. Clean Syn-Gas Since GB Gasifired produces an exceptionally clean Syn-Gas; heat exchangers remain clean and require minimal maintenance and downtime. Clean Syn-Gas can also be used to directly fire heating and drying applications such as sesame seed dryers, biscuit wafer plant, singeing machine, & rotary dryers, dry kilns, lime kilns etc or can be fed into Gas engine for power generation. Low Particulate Emissions GB Gasifired produce extremely low particulate emissions (typically < 50 mg/m 3 ) that may eliminate the requirement for air pollution control equipment such as multicores, electrostatic precipitators (ESPs) or bag house filters depending on the fuel type. High efficiency Due to the unique design GB Gasifired systems achieves extremely high efficiencies, up to 91% on some models. Indirect Gas Cooler The GB Gasifired system uses only indirect gas cooler and thereby eliminates water based gas cleaning. Thus, there is no sticky tar and tar contaminated effluents to be handled / disposed. Hot Gas Filter System The GB Gasifired - Vergassen incorporates unique hot gas fine filtration system (optional), a first of this kind, which can clean hot gas (temperatures up to 600 C). The dry gas filtration has an efficiency of over 96% for particulates over 10 micron size. It can typically produce a clean gas with less than 80 micrograms per m 3 of particulate matter. The compact size of the area Gasifired GB - Vergassen is an extremely compact gasification unit. Standard system with 1,000 kwe reactors, gas cleaning and handling system would take the space of only 15 x 17 meters (without fuel storage). The system design includes supporting construction and access platforms. The reactor does not need any foundation. So it is necessary to make ready only construction preparations and minor construction works. High Turn-Down Ratio The output of the gasifier can be reduced up to 1/3 of its maximum capacity while still maintaining stable operation. Quick Start and Shutdown The GB Gasifired - Vergassen series has extremely quick start capability and reach 75% of its capacity with 30 minutes of cold start and 15 minutes of restart (within 12 hours of shut down). Typically the shutdown time is less than 15 minutes. Idling Capability During Low Load Periods GB Gasifired can quickly fall into an idling mode where it can remain on standby for extended periods, such as a weekend shutdown, without consuming fuel, and then be brought back to full capacity within two hours. This enables operators to save fuel and avoids shutdown and restart during periods of low heat demand. Fuel Flexibility GB Gasifired can accommodate a wide range of wood fuels including wood chips, wood blocks, biomass briquettes, straw, waste garden, grass & other biomass from powdered to 10 cm sizes. Low Capital Cost GB Gasifired energy systems cost less because they are simpler in design, contain less equipment and have fewer moving parts. The ash collection system is also fully automatic, simpler, less expensive and easier to operate compared to conventional gasification systems. Low O&M Cost GB Gasifired systems are less expensive to operate and maintain because of their simple design and requirement for less equipment. Lower gas velocities and temperatures in the gasifier result in longer life and less refractory maintenance. Reduced particulate scouring results in less wear on the refractory in the gasifier.
7 Advantage of GB Gasifired technology Superior operational control, high turndown ratio, idling capability, Syn-Gas control and ability to eliminate ash melting, all contribute to making GB Gasifired systems very simple and easy to operate compared to conventional gasification/ combustion processes. This results in minimal operator intervention and contributes to low operating cost. Easy, Automatic Operation (Modern, user-friendly controller) GB Gasifired systems are fully automatic for unmanned operation with state-of-the-art controls. The GB Gasifier comes with an easy-to-use controller which manages the complete Gasification process and regulates supply to the burner/engine system. The control system is designed to provide safe, efficient operation of the energy system. Depending on the client s requirement, the GB Gasifired - Vergassen s operations may be totally or partly automatic. The optional automation modules include: 1. Reactor press control: To maintain the required gas quantity and quality accurately. 2. Load synchronizer: To control and regulate gas generation to adjust the load requirement. This eliminates possibility of excess gas pressurization / low heat availability and also eliminates the need to flare excess gas. 3. Automatic filter operation: To prevent problems such as choking and dust carry from the filter. 4. Load following control (optional): the gas generation (and consequently fuel wood consumption) is automatically controlled to follow the thermal load requirement. 5. Wide Range of Burners to suit any application (Fully Automatic Burners). 6. PLC panel, Remote control. Syn-Gas Possibilities of utilization: gas generator, acquired technology GB Gasifired can be used as a source of energy for heat and power (CHP gas engines designed to burn gas generator). syn-gas can be fed by pipeline from gasification units (which may be located outside the building works) into furnaces, etc., located in the building of the plant, and burn it in specially designed burners instead of fossil fuels such as oil / light diesel oil liquefied petroleum gas / compressed natural gas. thus it is possible to effectively replace the expensive liquid / gaseous fuel wood low-cost without changes in operation, temperature profiles, with temperature control and cleanliness in the area of business.
8 Syn-Gas Solid residues ash Ash content may vary markedly according to the kind of biomass in the range of 0,8 5% relative to the input material amount. The biomass ash is a clean fertiliser that does not contain hazardous substances. Recommended Syn-Gas Power and heat generation (cogeneration). Direct combustion of gas for technological processes. Production of electricity Gas burning in cogeneration units conversion to power with high efficiency of about 38 41,5%, thermal efficiency of about 45 49%, ORC modules Green Machine to utilize heat. Performance range from 80 kw to kw. Suppliers of cogeneration units: Guascor, Cummins, Jenbacher, Caterpillar, Mahindra, Ashok Leyland. Direct combustion Utilization of gas for heating Technological demand Reduction of costs for fuels over 50%. syn-gas can be introduced by piping from the gasifier to furnaces/fire chambers, etc. and can be combusted in specially-designed burners instead of fossil fuels (fuel oil / light diesel oil / diesel oil / liquefied petroleum gas / compressed natural gas. Hot water, vapour, technological air heating. GB Consulting s.r.o. design Kateřina Válková, ELVEKO CZ s. r. o., GB Consulting s.r.o. offers: We offer comprehensive solutions to your energy needs We provide an expert advice for the technology We make ready preparation of project documentation We arrange all preparation and realization of the project We offer engineering and construction activities related to the delivery of technology We guarantee maximum quality of delivered certified technology with verified references We put into practice highly efficient energy projects overall We offer solutions that maximize your profit while minimizing risk of operation We help significantly to reduce CO 2 emissions We supply just technological equipment certificate to the most stringent environmental requirements and standards GB Consulting s. r. o. Hudcova 533/78c, Brno, Czech Republic - Europe tel.: , info@gbconsulting.cz, info@gbgasifired.com
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