Co-gasification of wood and polyethylene with the aim of CO and H2 production

This article describes the gasification of polyethylene–wood mixtures to form syngas (H₂ and CO) with the aim of feedstock recycling via direct fermentation of syngas to ethanol. The aim was to determine the effects of four process parameters on process properties that give insight into the efficiency of gasification in general, and particularly into the optimum gasification conditions for the production of ethanol by fermentation of producer gas. Gasification experiments (fluidized bed, 800°–950°C) were done under different conditions to optimize the composition of syngas suitable for fermentation purposes. The data obtained were used for statistical analysis and modeling. In this way, the effect of each parameter on the process properties was determined and the model was used to predict the optimum gasification conditions. The parameters varied during the experiment were gasification temperature, equivalence ratio, the ratio of plastic to wood in the feed, and the amount of steam added to the process. The response models obtained proved to be statistically significant in the experimental domain. The optimum gasification conditions for maximization of carbon monoxide and hydrogen production were identified. The conditions are: temperature 900°C, equivalence ratio 0.15, amount of plastic in the feed 0.11 g/g feed, and amount of steam added 0.42 g/g feed. These optimum conditions are at the edge of the present experimental domain. The maximum combined CO and H₂ efficiency was 42%, and for the maximum yield of CO and H₂ it is necessary to minimize the polyethylene content, minimize the added steam and the equivalence ratio, and maximize temperature.     

Gasification and its emission characteristics for dried sewage sludge utilizing a fluidized bed gasifier

Various research has attempted to determine the proper treatment of sewage sludge, including thermal technologies. Efficient thermal technologies have been focused on because of their energy saving/energy recovery. Gasification technology can be considered one of these approaches. In this study, the characteristics of gasification reactions were investigated with the aim of finding fundamental data for utilizing sewage sludge as an energy source. For the experiments on sewage sludge gasification reaction characteristics, a laboratory-scale experimental apparatus was set up with a fluidizing bed reactor of 70-mm inner diameter and 600-mm total height using an electric muffle furnace. The experimental materials were prepared from a sewage treatment plant located in Seoul. The reaction temperature was varied from 630 to 860°C, and the equivalence ratio from 0.1 to 0.3. The gas yields, compositions of product gas, and cold gas efficiencies of product gas were analyzed by GC/TCD and GC/FID installed with a carboxen-1000 column. The experimental results indicated that 800°C, ER 0.2 was an optimum condition for sewage sludge gasification. The maximum yield of product gas was about 44%. Producer gas from experiments was mainly composed of hydrogen, carbon monoxide, carbon dioxide, and methane. The cold gas efficiency of sewage sludge gasification was about 68%. The H₂/CO ratio and CO/CO₂ ratio were about 1.1 and 1.4, respectively, in optimum reaction conditions. Gaseous pollutants such as SO₂, HCl, NH₃, H₂S, and NO₂ were also analyzed at various gasification/combustion conditions, and their gaseous products were compared, showing significantly different oxidized product distributions.     

Catalytic gasification of tars from a dumping site

The work deals with catalytic gasification, pyrolysis and non-catalytic gasification of tar from an industrial dumping site. All experiments were carried out in a vertical stainless steel gasification reactor at 800 °C. Crushed calcined dolomite was used as the gasification catalyst. Parameters such as addition of water and air, and the influence of the catalyst in regard to the composition of the process gas were investigated. The catalytic gasification experiment in the steady state produced process gas with the composition: 56 % of H₂, 9 % of CO, 11 % of CH₄ and 12 % of CO₂ (mol.%). Concentration of the C₂ fraction was lower than 1 mol.%. Volume flow of air was later changed from 120 to 230 ml min^?1 reducing the amount of hydrogen to 51 mol.% and that of methane to 10 mol.%. Process gas created in a non-catalytic gasification process contained 26–30 mol.% of methane, 13–15 mol.% of carbon monoxide and 15–17 mol.% of the C₂ fraction and lower amounts of hydrogen (20 mol.%) and carbon dioxide (2–3 mol.%). The highest apparent conversion of tar was reached in the catalytic gasification processes. A higher rate of catalyst deactivation can be observed when water or air is not added.     

Gasification and reforming of biomass and waste samples by means of a novel catalyst

This study conducted gasification and catalytic reforming experiments with the expectation of obtaining new advantages on energy recovery and aimed for the development of an effective catalyst. Initially, the use of thermal gasification technology for waste treatment in line with waste-to-energy strategies was reviewed. Technological systems which have gasification were classified and their current status was discussed. Then, the results of gasification and reforming experiments showed that product gas with 50 % H₂ or more was obtained using a Ni catalyst on a mesoporous silica–based SBA-15 support (NiO/SBA-15), which we newly developed. Experiments using wood feedstock revealed that H₂ production by the catalyst was better when the NiO content was 20 % (W/W) or more than when another catalyst or the Ni catalyst with a lower Ni loading was used. Tar formation as a by-product was also well controlled by the catalyst, and use of a catalyst with 40 % NiO reduced the tar concentration to less than 0.2 g/\( {\text{m}}^{3}_{\text{N}} \). Experiments using a mixed feedstock of wood and RPF resulted in an increase in hydrocarbon concentration because of insufficient reforming. This finding suggests that future work is required to find a better solution to wood and RPF co-gasification.     

The mixing and segregation characteristics of rice straw in a cylindrical bubbling fluidized bed

In the present study, an experiment was performed to investigate the mixing and segregation characteristics of standard sand and rice straw particles in a cylindrical bubbling fluidized bed. The mass ratio (rice straw/standard sand = 0.5–1.25 %) of two particles and superficial gas velocity (0.13–0.18 m/s) were changed as experimental variables. The pressure drop curve and Kramer’s equation were used to determine the minimum fluidization velocity and mixing index, respectively. In all cases, the mixing index was the lowest at U/U _mf = 1.15. Based on the point of U/U _mf = 1.15, the segregation region and mixing region were observed. In the segregation region, mass ratio of 0.75 % showed the lowest mixing index. At the U/U _mf = 1.23 which was selected as the starting of fast pyrolysis considering residence time and the previous fast pyrolysis experiment, mass ratio of 1.25 % showed the highest mixing index which was 0.90.     

Design and first experimental results of a bubbling fluidized bed for air gasification of plastic waste

Plastic wastes have an especially high potential for use as alternative fuels, considering their high heating value and their large and stable availability. They could be used in electricity production based on gasification technologies, wherein electricity is produced in engines by means of the conversion of plastic wastes into a valuable gas. However, there are still some technical barriers to overcome before this technology can access the commercial stage, and further scientific research is needed to gain deeper understanding of the process and to be able to control and optimize it. This research presents the design and first experimental results of a bubbling fluidized bed gasifier conceived for the gasification of actual plastic residues. The experimental tests revealed that the selection and design of the reactor were adequate and proved some of the advantages of using plastic as a fuel, related in part to the absence of ashes and char. A valuable syngas over 5 MJ/m³ was generated, which contained a considerable fraction of methane as well as hydrogen and carbon monoxide as main combustible gases. The highest efficiency was achieved when the equivalence ratio was increased to 0.35, reaching 61 % in terms of cold gas efficiency and 66 % carbon conversion.     

Biodegradation characteristics of organic matters in swine carcasses under different initial operating conditions of simulated anaerobic lysimeter

This study was aimed to investigate the biodegradation characteristics of organic matters in swine carcasses. The lysimeters were simulated with different initial operating conditions: 30 % volumetric moisture content and no sludge addition for lysimeter A (control), 30 % volumetric moisture content and anaerobic sludge addition for lysimeter B, and 40 % volumetric moisture content and anaerobic sludge addition for lysimeter C. The degradation efficiency (18.4 %) of lysimeter B was higher than that (15.2 %) of lysimeter A due to anaerobic sludge addition. Lysimeter B showed higher CH₄ yield (15.6 L/kg VS) and CH₄ production rate (0.41 L/kg VS days) compared to lysimeter A by 31 % and 14 %, respectively. In addition, the degradation efficiency improved from 18.4 % (lysimeter B) to 26.3 % (lysimeter C) by increasing volumetric moisture content. The CH₄ yield (22.9 L/kg VS) and CH₄ production rate (0.68 L/kg VS days) of lysimeter C were higher than those of lysimeter B, respectively. Total organic carbon (TOC) removed in lysimeter C was converted to leachate (20.3 %) and gas (6.0 %), whose values were higher than those of lysimeter A and B. These results demonstrated that the proper control of initial operating conditions could accelerate the anaerobic degradation of organic matters in swine carcasses.     

An innovative example of herb residues recycling by gasification in a fluidized bed

A utilization way of herb residues is designed to convert herb residues to gas fuel in industrial-scale by a circulating fluidized bed gasifier in this paper. The product gas is used in the production of Chinese medicine, and the heat of the flue gas from the boiler can be used in herb residues drying to realize the energy recycling and no herb residues discharge. The gasification characteristics of herb residues in the circulating fluidized bed of 300 kg/h were investigated for about 200 h. The results indicated that the gas composition and tar yield were affected by biomass flow rate, equivalence ratio (ER), moisture content and char circulating. The lower heating value of product gas was 4–5 MJ/m³ using herb residues as feedstock. When mean biomass flow rate was at 5.5 kg m^?2 s^?1 and ER at 0.35, the product gas reached a good condition with lower heating value of 4.89 MJ/m³ and cold gas efficiency of 62.36%. When the moisture content changed from 12.5% to 18.7%, the concentrations of H₂, CO and CO₂ changed from 4.66% to 6.92%, 11.23% to 10.15%, and 16.55% to 17.82% respectively, and the tar content in gas decreased from 15.1 g/m³ to 14.4 g/m³ when the moisture content increased from 12.5% to 15.4%. There are metal oxides in the ash of herb residues, especially CaO, MgO, K₂O, Al₂O₃, and Fe₂O₃ which have obvious function on tar catalytic decomposition. The ash that attaches to the char particles can decrease the tar yield and improve the quality of gas after returning to the gasifier.     

Thermal valorization of post-consumer film waste in a bubbling bed gasifier

The use of plastic bags and film packaging is very frequent in manifold sectors and film waste is usually present in different sources of municipal and industrial wastes. A significant part of it is not suitable for mechanical recycling but could be safely transformed into a valuable gas by means of thermal valorization. In this research, the gasification of film wastes has been experimentally investigated through experiments in a fluidized bed reactor of two reference polymers, polyethylene and polypropylene, and actual post-consumer film waste. After a complete experimental characterization of the three materials, several gasification experiments have been performed to analyze the influence of the fuel and of equivalence ratio on gas production and composition, on tar generation and on efficiency. The experiments prove that film waste and analogue polymer derived wastes can be successfully gasified in a fluidized bed reactor, yielding a gas with a higher heating value in a range from 3.6 to 5.6 MJ/m³ and cold gas efficiencies up to 60%.     

Reduction of tar using cheap catalysts during sewage sludge gasification

Solid-fuel conversion or gasification study of sewage sludge and energy recovery has become increasingly important because energy recovery and climate change are emerging issues. Various types of catalysts, such as dolomite, steel slag and calcium oxide, were tested for tar reduction during the sewage sludge gasification process. For the experiments on sewage sludge gasification reactions and tar reduction using the catalysts, a fixed bed of laboratory-scale experimental apparatus was set up. The reactor was made of quartz glass using an electric muffle furnace. The sewage sludge samples used had moisture contents less than 6%. The experimental conditions were as follows: sample weight was 20 g and reaction time was 10 min, gasification reaction temperature was from 600 to 800°C, and the equivalence ratio was 0.2. The quantity of catalysts was 2–6 g, and temperatures of catalyst layers were 500–700°C. As the reaction temperature increased up to 800°C, the yields of gaseous products and liquid products increased, whereas char and tar products decreased, showing effects on gas product compositions. These results were considered to be due to the increase of the water-gas reaction and Boudouard reaction. In the case of experiments with catalysts, dolomite (4 g), steel slag (6 g) and calcium oxide (6 g) were used. When the temperature of catalysts increased, the weight of the tar produced decreased with different cracking performances by different catalysts. Reforming reactions were considered to occur on the surface of dolomite, steel slag and calcium oxide, causing cracking of the hydrocarbon structure, which eventually showed reduced tar generation.     

H₂-rich syngas production by fluidized bed gasification of biomass and plastic fuel

This paper reports the results of gasification tests using a catalytic fluidized bed gasifier to obtain a H₂-rich stream by feeding different pellets made of wood, biomass/plastic and olive husks to the gasifier. The effects of both the steam supply and an in-bed catalyst on gasifier performance have been investigated. In general, pelletization was an effective pre-treatment for improving the homogeneity of the fuel and the reliability of the feeding devices. The use of biomass/plastic pellets in a catalyst bed yielded good results in terms of the hydrogen concentration (up to 32% vol.), even if an increase in tar production and in the fine/carbon elutriation rate was observed in comparison with wood pellets.     

Gasification applicability study of polyurethane solid refuse fuel fabricated from electric waste by measuring syngas and nitrogenous pollutant gases

To recycle polyurethane foam waste generated from electric appliance recycling centers for use as fuel in a gasification process, polyurethane solid refuse fuel fabricated as pellets was analyzed for the characteristics of elemental composition, proximate analysis, heating value, and thermo-gravimetric testing. It has a high heating value of 29.06 MJ/kg with a high content of combustibles, which could be feasibly used in any thermal process. However, the nitrogen content, of up to 7 %, was comparably higher than for other fuels such as coal, biomass, and refuse-derived fuel, and may result in the emission of nitrogenous pollutant gases of HCN and NH₃. By conducting gasification experiments on polyurethane solid refuse fuel in a fixed-bed reactor, a syngas with a heating value of 9.76 kJ/m³ and high content of both H₂ and CO were produced with good gasification efficiency; carbon conversion 54 %, and cold gas efficiency 60 %. The nitrogenous pollutant gases in syngas were measured at the concentrations of 160 ppm hydrogen cyanide and 40 ppm ammonia, which may have to be reduced using proper cleaning technologies prior to the commercialization of gasification technology for polyurethane waste.     

Preparation and characterization of high surface area activated carbon from pine wood sawdust by fast activation with H<Subscript>3</Subscript>PO<Subscript>4</Subscript> in a spouted bed

Activated carbons were produced from waste pine wood sawdust using fast activation with H₃PO₄ in a spouted bed. In this study, activation temperature was set as 800 °C, and activation time ranged from 1 to 15 min. Experimental results show that sawdust impregnated with higher mass ratio of H₃PO₄ would be agglomerated in spouted bed, and difficult to fluidize. Therefore, an amount of quartz sand was added to assist for good fluidization. Fluidization of particle can improve the BET surface area or micropore volume of activated carbons. High BET surface area activated carbons can be obtained with activation time of only 1–5 min by combining the fluidization and H₃PO₄ fast activation. The obtained activated carbons contained developed pore structure and abundant surface functional groups (carboxyl, carbonyl and P-containing groups) by SEM–EDS, FTIR and XPS techniques. The particles of impregnation ratio of 1:1 can achieve fluidization without adding the quartz sand, which was convenient for experimental operation and even industrial production, and the BET surface area can reach more than 1000 m²/g in activation time of only 5 min.     

Study of hydrodynamic characteristics in a circulating fluidized bed gasifier for plastic waste by computational fluid dynamics modeling and simulation

For designing an efficient circulating fluidized bed reactor, understanding the complex hydrodynamic characteristics in the reactor is required. Hence, in the present study, the modeling and simulation of the circulating fluidized bed gasifier using plastic waste were carried out with Eulerian-Granular approach. Several cases were investigated as changing superficial gas velocities or sizes of plastic waste particle. Firstly, cases were examined with four different velocities when the particle diameter is 1 mm. At the gas velocity of 6 or 8 m/s, gas volume fraction is more than 95 % throughout the reactor and particle velocity has positive value overall. Therefore, a circulating fluidized bed seems to be formed in both cases. Comparing those two cases, better solid mixing can be expected considering the mass fraction and solid velocity at the superficial gas velocity of 6 m/s. Thus this case was further studied for the effect of particle size. As the diameters of plastic waste particle are 1 or 3 mm, it is considered that a circulating fluidized bed is formed. And plastic waste and sand particles are well mixed throughout the reactor. However, the particle diameter increases over 3 mm then, it is very hard to maintain circulating fluidization condition.     

Limitations for heavy metal release during thermo-chemical treatment of sewage sludge ash

Phosphate recycling from sewage sludge can be achieved by heavy metal removal from sewage sludge ash (SSA) producing a fertilizer product: mixing SSA with chloride and treating this mixture (eventually after granulation) in a rotary kiln at 1000 ± 100 °C leads to the formation of volatile heavy metal compounds that evaporate and to P-phases with high bio-availability. Due to economical and ecological reasons, it is necessary to reduce the energy consumption of this technology. Generally, fluidized bed reactors are characterized by high heat and mass transfer and thus promise the saving of energy. Therefore, a rotary reactor and a fluidized bed reactor (both laboratory-scale and operated in batch mode) are used for the treatment of granulates containing SSA and CaCl₂. Treatment temperature, residence time and - in case of the fluidized bed reactor - superficial velocity are varied between 800 and 900 °C, 10 and 30 min and 3.4 and 4.6 m s⁻¹. Cd and Pb can be removed well (>95 %) in all experiments. Cu removal ranges from 25% to 84%, for Zn 75-90% are realized. The amount of heavy metals removed increases with increasing temperature and residence time which is most pronounced for Cu.In the pellet, three major reactions occur: formation of HCl and Cl₂ from CaCl₂; diffusion and reaction of these gases with heavy metal compounds; side reactions from heavy metal compounds with matrix material. Although, heat and mass transfer are higher in the fluidized bed reactor, Pb and Zn removal is slightly better in the rotary reactor. This is due the accelerated migration of formed HCl and Cl₂ out of the pellets into the reactor atmosphere. Cu is apparently limited by the diffusion of its chloride thus the removal is higher in the fluidized bed unit.     

The behaviors of H2, CH4, C2H4 and C3H6 from the decomposition of polypropylene by NiO/Si–Al catalyst

The purpose of this study was to investigate the possibility of light gases produced from polypropylene, specifically hydrogen. In particular, we examined the effect of operating conditions on gaseous product and compositions in the catalytic cracking of polypropylene. We also characterized the gaseous product generated from polypropylene cracking. The feedstock (2.0 g) mixed with NiO/SiO₂–Al₂O₃ (Si–Al) was used, under non-isothermal conditions at low temperature range between 380 and 500 °C. Argon gas was used to carry the pyrolyzed gas, and the gas collected in a tedlar bag was analyzed for its behavior. We observed the behavior of major gases (H₂, CH₄, C₂H₄ and C₃H₆, etc.) according to reaction time and temperature. Finally, the effect of reaction conditions on evolved gases from catalytic cracking of polypropylene was analyzed.     

Fate and behavior of selected heavy metals with mercury mass distribution in a fluidized bed sewage sludge incinerator

In this paper, emission and distribution behavior of six heavy metals (As, Cd, Cr, Ni, Pb, and Hg), particulate matter and mass distribution of mercury within the different streams of a fluidized bed sewage sludge incinerator are presented. At the inlet of air pollution control devices (APCDs); Cd, Cr, Ni and Pb were mainly enriched in coarse particles; comparatively As content was higher in fine particles (<PM_2.5). The concentration of heavy metals in total particulate matter and PM_2.5, at the inlet of APCDs, were in the order of Cr > Ni > Pb > As > Cd. Mercury was almost always distributed in flue gas. Metals, other than mercury, were efficiently removed in APCDs and their concentrations in bottom ash, with fly ash being higher, whereas for that in wastewater, then waste sand was lesser. Overall mercury removal efficiency of APCDs was 98.6 %. More than 83.3 % of mercury was speciated into oxidized form at the inlet of APCDs, attributed by higher chlorine content in sludge. Mercury was mainly distributed in wastewater (78.4 %), wastewater from a spray dry reactor (16.8 %), fly ash in a hopper (3.4 %) and flue gas (1.4 %). This result is one of the first for data to be obtained; more experiments are required to control emission from such sources.     

Stabilization of sewage sludge in the presence of nanoscale zero-valent iron (nZVI): abatement of odor and improvement of biogas production

The potential benefits of nanoscale zero-valent iron (nZVI) on sludge stabilization, either the abatement of odor or the improvement of biogas production, were investigated in this study. Two commercial-grade microscale iron powders were also utilized for comparison. Adding 0.10 wt% of nZVI in sludge during anaerobic incubation significantly reduced the concentration of H₂S in biogas by 98.0 % (96.2–98.9 %), probably attributed by reactions between sulfides and the neo-formed hydrous Fe(II)/Fe(III) oxides layer at the surface of ZVI nanoparticles. Meanwhile, the percentage of P in bioavailable fractions decreased from 76.8 to 52.5 %, possibly due to the formation of vivianite [Fe₃(PO₄)₂]. Furthermore, 0.10 wt% of nZVI in anaerobic digestion for 17 days enhanced the concentration of CH₄ in biogas by 5.1–13.2 % and improved the production of biogas and methane by 30.4 and 40.4 %, respectively. The amendment of iron nanoparticles during anaerobic digestion can not only effectively reduce H₂S in biogas, but also potentially boost methane production significantly.     

Gasification of waste plastics by steam reforming in a fluidized bed

The process of producing synthetic gas from waste plastics by steam reforming was investigated. To evaluate this process, the steam reforming of the oils derived from low-density polyethylene and polystyrene were carried out using a laboratory-scale fluidized bed of Ni-Al₂O₃ catalysts. The performance of gasification in terms of carbon conversion, gas yield, and gas compositions was examined. Although oils derived from plastics contain many kinds of heavy hydrocarbons and aromatics, they were well gasified at temperatures above 1023 K with a steam/carbon ratio of 3.5 and a weight hourly space velocity of 1 h⁻¹. The hydrogen content of the product gas was very high at approximately 72 vol% for polyethylene-derived oil and 68 vol% for polystyrene-derived oil. These compositions agreed well with the values calculated from chemical equilibrium.     

Fluid bed gasification – Plasma converter process generating energy from solid waste: Experimental assessment of sulphur species

Often perceived as a Cinderella material, there is growing appreciation for solid waste as a renewable content thermal process feed. Nonetheless, research on solid waste gasification and sulphur mechanisms in particular is lacking. This paper presents results from two related experiments on a novel two stage gasification process, at demonstration scale, using a sulphur-enriched wood pellet feed.Notable SO₂ and relatively low COS levels (before gas cleaning) were interesting features of the trials, and not normally expected under reducing gasification conditions. Analysis suggests that localised oxygen rich regions within the fluid bed played a role in SO₂’s generation. The response of COS to sulphur in the feed was quite prompt, whereas SO₂ was more delayed. It is proposed that the bed material sequestered sulphur from the feed, later aiding SO₂ generation. The more reducing gas phase regions above the bed would have facilitated COS – hence its faster response. These results provide a useful insight, with further analysis on a suite of performed experiments underway, along with thermodynamic modelling.