integrated biochar production systembiochar-us.org/sites/default/files/presentations/2.2.1...
TRANSCRIPT
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Measuring performance of a biochar machine with belt dryer and gasifier generator set
David Carter, P.E.Sr. Research EngineerSchatz Energy Research Center
http://www.schatzlab.org/
Integrated Biochar Production SystemUsing Forest Residuals
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» Background» Biochar Production Process
» Technology Description
» Adding Waste Heat Recovery Dryer» Test Objectives
» Results
» Integrated Biochar Production System» System Overview
» Results
» Conclusions
Presentation Outline
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Syngas,Tars
Fuel
Char
Gasification
Biochar is produced through thermal decomposition of biomass in an oxygen-limited environment, a process known as gasification.
Biochar Production
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1) Biomass undergoes gasification in the reactor.2) Char is separated from the syngas.3) Syngas is burned in a flare.4) Biochar is collected.
Process Diagram for Biochar Solutions, Inc. Machine
syngas air
exhaust
reactor char separation char collection
flare
feedstock
1 2
3
4
syngas blower
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Biochar Process Flow
Reactor
Separator
Flare
Char Collection
SyngasBlower
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Feedstock HopperReactor
Feeding System for Biochar Machine
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Lessons Learned from Testing this Machine
» Moisture content of the feedstock greatly impacts production rates and labor costs.
» A reliable power source is required to operate at remote locations.
» Utilize waste heat from flare to dry incoming feedstock
» Assess suitability of biomass gasifier generator set to power biochar machine
Lesson Proposed Solution
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Moisture Content is an Economic DriverDuring testing of this machine in 2014, moisture content was found to greatly influence labor hours and operational costs.
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Waste Heat Recovery for Feedstock Drying» The biochar flare is a significant source of high quality waste heat.
» This heat can be used as the input to a belt dryer.
» If successful, this could increase the range of acceptable moisture contents, and decrease the operational effort of the biochar machine.
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Electricity Generation from Biomass Side Stream» Biomass is readily available on location
» Power can be generated from a side stream of biomass to offset diesel costs
» A small gasifier generator can meet the electrical demand
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Gasifier Technology Description
Image from All Power Labs, Inc.
All Power Labs, Inc. PP20 Gasifier
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Dryer Study
» Install heat exchange equipment.
» Instrument the dryer with temperature, relative humidity, flow rate, and power meters.
» Automate the conveyance system from dryer inlet to biochar production.
Test Objectives» Determine best operating
conditions for dryer by changing:» Hot air flow rate and temperature
» Dryer belt speed and capacity
Installation
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Dryer Study: Results» Tested two heat exchanger (HEX) blower speeds; higher flow lower temperature
» Tested two dryer belt speeds; higher belt speed higher throughput
» Best drying achieved at high blower speed.
» Adjust dryer belt speed to match consumption rate of biochar machine.
0%
10%
20%
30%
0 200 400 600 800
Moi
stur
e C
onte
nt L
oss
Bone Dry Throughput, kg/hr
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Exhaust86% RHCool Air Biomass In
41% MC
Biomass Out 19% MC
Process Heat – 50 kW at 157°CMixed Air
129°C
Throughput: 245 kg/hr (bone dry)Moisture Removal: 22%
Electric Load 3.5 kW
128°C 35°C 34°C
Dryer Operating ConditionsProcess conditions at high HEX blower, high belt speed.
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Project Objectives for Integrated Operation
Objectives
» Determine system throughput during 8 hours operation.
» Measure labor requirements
» Using information from the dryer study, and integrated system was setup to operate the biochar machine.
» The biomass gasifier generator was connected to the system to validate its performance.
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Biochar Machine: Biochar Solutions, Inc.
Gasifier Generator: 20 kW PP20, All Power Labs, Inc.
Dryer: 123B Belt-o-matic, Norris Thermal Technologies
Date: June 2016
Location: Old Harwood Mill in Branscomb, California
Feedstock: Green Redwood Chips
Integrated System Background Information
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Gasifier
Backup Diesel Generator
Biochar Machine
Dryer
Field Testing Setup
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Integrated Operation Noise Level
91 dB
84 dB @ 50 ft
76 dB @ 100 ft
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Gasifier Process Flow
23 kg/hr @ 22%
10 kW
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» Mass and energy flows during the test are shown below
System Integration Flow Diagram
BiocharMachine
410 kg/hr@ 22%
79 kg/hrbiochar
Dryer
523 kg/hr@ 36%
433 kg/hr@ 22%
42 kW thermal7 kW electric
23 kg/hr@ 22%
Gasifier
3 kW electric
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» The biochar machine uses 107 kWhe to produce 1 ton of biochar.
» Gasifier generator can offset diesel fuel by using a sidestream of biomass feedstock.
Benefits of System Integration
Diesel Generator Biomass GasiferFuel Rate at 9 kW load 0.9 gal/hr 18 kg/hr (dry basis)Fuel to Produce 1 ton Biochar 10.4 gal 205 kg (dry basis)
Electricity Usage
» Utilize waste heat to dry incoming feedstock.
» Without dryer, maximum moisture content was 25%
» With the dryer, incoming moisture content can be up to 40%
Increase Range of Acceptable Moisture Contents
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Conclusions» Belt dryer works well with waste heat from flare, can remove up to 25% moisture.
» Integrating belt drying into system increases the acceptable moisture content of the biochar machine from 25% to 40%.
» The gasifier generator can meet the electrical demand of the system with additional maintenance costs.