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.     

Gasification characteristics of sewage sludge combined with wood biomass

The gas products from gasification processes have been considered to have some limitations in gas composition and heating value from the previous studies. Gasification characteristics of sewage sludge and wood mixture were investigated using different mixing ratios with the purpose of better quality of gas product suitable for energy/power generation. The gasification experiment was performed by an indirectly heated fluidized bed reactor. As reaction temperature increased from 600 to 900 °C, the yield of gas product increased with higher generation of CO, H₂ and CH₄ by more activated gas conversion reactions. As the equivalence ratio increased from 0.2 to 0.4, composition ratio of CO₂ increased while CO, CH₄, H₂ decreased as expected. Several operating variables including mixing ratio of wood with dried sludge were also tested. From this initial stage of experiment, optimal operating conditions for the bubbling fluidized bed gasifier, could be considered 900 °C in temperature; 0.2 in equivalence ratio and 40 % in wood mixing ratio within test variables range. These results will be more thoroughly investigated for the application to the larger scale pilot system.     

Hydrogen-rich fuel gas production from refuse plastic fuel pyrolysis and steam gasification

In this study, experimental conditions were optimized to maximize the production of hydrogen gas from refuse plastic fuel (RPF) by pyrolysis and steam gasification processes conducted in a laboratory-scale reactor. We carried out gasification using 10-g RPF samples at different temperatures (700°-1000°C) with and without steam. The effect of the amount of steam (0–0.25 g/min) for RPF steam gasification was also studied. The effect of K₂CO₃ as a catalyst on these processes was also investigated. Experimental results showed that the hydrogen gas yield increased with temperature; with respect to the gas composition, the hydrogen content increased mainly at the expense of other gaseous compounds, which highlights the major extension of secondary cracking reactions in the gaseous fraction at higher temperatures.     

Gasification of refuse derived fuel in a fixed bed reactor for syngas production

Steam gasification of two different refuse derived fuels (RDFs), differing slightly in composition as well as thermal stability, was carried out in a fixed-bed reactor at atmospheric pressure. The proximate and ultimate analyses reveal that carbon and hydrogen are the major components in RDFs. The thermal analysis indicates the presence of cellulose and plastic based materials in RDFs. H2 and CO are found to be the major products, along with CO2 and hydrocarbons resulting from gasification of RDFs. The effect of gasification temperature on H2 and CO selectivities was studied, and the optimum temperature for better H2 and CO selectivity was determined to be 725 degrees C. The calorific value of product gas produced at lower gasification temperature is significantly higher than that of gas produced at higher process temperature. Also, the composition of RDF plays an important role in distribution of products gas. The RDF with more C and H content is found to produce more amounts of CO and H2 under similar experimental conditions. The steam/waste ratio showed a notable effect on the selectivity of syngas as well as calorific value of the resulting product gas. The flow rate of carrier gas did not show any significant effect on products yield or their distribution.     

Characterization of products obtained from pyrolysis and steam gasification of wood waste,RDF, and RPF

Pyrolysis and steam gasification of woody biomass chip (WBC) obtained from construction and demolition wastes, refuse-derived fuel (RDF), and refuse paper and plastic fuel (RPF) were performed at various temperatures using a lab-scale instrument. The gas, liquid, and solid products were examined to determine their generation amounts, properties, and the carbon balance between raw material and products.The amount of product gas and its hydrogen concentration showed a considerable difference depending on pyrolysis and steam gasification at higher temperature. The reaction of steam and solid product, char, contributed to an increase in gas amount and hydrogen concentration. The amount of liquid products generated greatly depended on temperature rather than pyrolysis or steam gasification. The compositions of liquid product varied relying on raw materials used at 500 °C but the polycyclic aromatic hydrocarbons became the major compounds at 900 °C irrespective of the raw materials used. Almost fixed carbon (FC) of raw materials remained as solid products under pyrolysis condition whereas FC started to decompose at 700 °C under steam gasification condition.For WBC, both char utilization by pyrolysis at low temperature (500 °C) and syngas recovery by steam gasification at higher temperature (900 °C) might be practical options. From the results of carbon balance of RDF and RPF, it was confirmed that the carbon conversion to liquid products conspicuously increased as the amount of plastic increased in the raw material. To recover feedstock from RPF, pyrolysis for oil recovery at low temperature (500 °C) might be one of viable options. Steam gasification at 900 °C could be an option but the method of tar reforming (e.g. catalyst utilization) should be considered.     

Hydrogen-rich synthesis gas production from waste wood via gasification and reforming technology for fuel cell application

The purpose of this study was to establish a fuel process for an advanced power generation system in which hydrogen-rich synthesis gas, as the fuel for the molten carbonate fuel cell (MCFC), can be extracted from biomass via gasification and reforming technologies. Experiments on waste wood gasification were performed using a bench-scale gasification system. The main factors influencing hydrogen generation in the noncatalytic process and in the catalytic process were investigated, and temperature was identified as the most important factor. At 950°C, without employing a catalyst, hydrogen-rich synthesis gas containing about 54 vol% hydrogen was extracted from feedstock with appropriately designed operation parameters for the steam/carbon ratio and the equivalence ratio. However, by employing a commercial steam reforming catalyst in the reforming process, similar results were obtained at 750°C.     

Production of hydrogen by steam gasification of dehydrochlorinated poly(vinyl chloride) or activated carbon in the presence of various alkali compounds

Steam gasification of dehydrochlorinated poly(vinyl chloride) (PVC) or activated carbon was carried out in the presence of various alkali compounds at 3.0 MPa and 560°C–660°C in a batch reactor or in a semi-batch reactor with a flow of nitrogen and steam. Hydrogen and sodium carbonate were the main products, and methane and carbon dioxide were the minor products. Yields of hydrogen were high in the presence of sodium hydroxide and potassium hydroxide. The acceleration effect of the alkali compounds on the gasification reaction was as follows: KOH > NaOH > Ca(OH)₂ > Na₂CO₃. The rate of gasification increased with increasing partial steam pressure and NaOH/C molar ratio. However, the rate became saturated at a molar ratio of NaOH/C greater than 2.0.     

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.     

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.     

Modeling and comparative assessment of municipal solid waste gasification for energy production

Gasification is the thermochemical conversion of organic feedstocks mainly into combustible syngas (CO and H₂) along with other constituents. It has been widely used to convert coal into gaseous energy carriers but only has been recently looked at as a process for producing energy from biomass. This study explores the potential of gasification for energy production and treatment of municipal solid waste (MSW). It relies on adapting the theory governing the chemistry and kinetics of the gasification process to the use of MSW as a feedstock to the process. It also relies on an equilibrium kinetics and thermodynamics solver tool (Gasify®) in the process of modeling gasification of MSW. The effect of process temperature variation on gasifying MSW was explored and the results were compared to incineration as an alternative to gasification of MSW. Also, the assessment was performed comparatively for gasification of MSW in the United Arab Emirates, USA, and Thailand, presenting a spectrum of socioeconomic settings with varying MSW compositions in order to explore the effect of MSW composition variance on the products of gasification. All in all, this study provides an insight into the potential of gasification for the treatment of MSW and as a waste to energy alternative to incineration.     

Production of gaseous fuel from refuse plastic fuel via co-pyrolysis using low-quality coal and catalytic steam gasification

In this study, refuse plastic fuel (RPF) was copyrolyzed with low-quality coal and was gasified in the presence of a metal catalyst and steam. Some metal catalysts, such as Ni, NiO, and Mg, and mixtures of these with base promoters such as Al₂O₃ and Fe₂O₃ were employed in the pyrolysis and gasification processes to convert the synthesis gas into more valuable fuel gas. The operating temperatures for the pyrolysis and gasification were between 700° and 1000°C. The experimental parameters were the operating temperature, catalyst type, basic promoter type, and steam injection amount. Solid fuel samples (5 g) were fed into a semibatch-type quartz tube reactor when the reactor reached the designated temperature. The synthesis gas was analyzed by gas chromatography. The use of low-quality coal as fuel in co-pyrolysis with RPF was explored. For the co-pyrolysis of RPF and low-quality coal, the effectiveness of the catalysts for fuel gas production followed the order Mg > NiO > Ni. In catalytic gasification of RPF, the addition of Al₂O₃ seemed to reduce the activity of the corresponding catalysts Ni and Mg. The maximum fuel gas yield (92.6%) was attained when Mg/Fe₂O₃ was used in steam gasification at 1000°C.     

Removal of H2S using molten carbonate at high temperature

Gasification is considered to be an effective process for energy conversion from various sources such as coal, biomass, and waste. Cleanup of the hot syngas produced by such a process may improve the thermal efficiency of the overall gasification system. Therefore, the cleanup of hot syngas from biomass gasification using molten carbonate is investigated in bench-scale tests. Molten carbonate acts as an absorbent during desulfurization and dechlorination and as a thermal catalyst for tar cracking. In this study, the performance of molten carbonate for removing H₂S was evaluated. The temperature of the molten carbonate was set within the range from 800 to 1000 °C. It is found that the removal of H₂S is significantly affected by the concentration of CO₂ in the syngas. When only a small percentage of CO₂ is present, desulfurization using molten carbonate is inadequate. However, when carbon elements, such as char and tar, are continuously supplied, H₂S removal can be maintained at a high level.To confirm the performance of the molten carbonate gas-cleaning system, purified biogas was used as a fuel in power generation tests with a molten carbonate fuel cell (MCFC). The fuel cell is a high-performance sensor for detecting gaseous impurities. When purified gas from a gas-cleaning reactor was continuously supplied to the fuel cell, the cell voltage remained stable. Thus, the molten carbonate gas-cleaning reactor was found to afford good gas-cleaning performance.     

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.     

Characterization of syngas produced from MSW gasification at commercial-scale ENERGOS Plants

Characterization of the syngas produced in the gasification process has been performed at commercial-scale Energy-from-Waste plants under various conditions of lambda value and syngas temperature. The lambda value from the gasification process is here defined as the ratio of the gasification air to the total stoichiometric air for complete combustion of the fuel input. Evaluation of the syngas calorific value has been performed by three different methods, i.e., estimation of the syngas calorific value from continuous in-line process measurements by mass and energy conservation equations, measurement of the syngas composition based on gas chromatography and calculation of the Gross Calorific Value from the measured composition, and direct continuous measurement of the calorific value using based on gas calorimeter.     

Prediction of syngas quality for two-stage gasification of selected waste feedstocks

This paper compares the syngas produced from methane with the syngas obtained from the gasification, in a two-stage reactor, of various waste feedstocks. The syngas composition and the gasification conditions were simulated using a simple thermodynamic model. The waste feedstocks considered are: landfill gas, waste oil, municipal solid waste (MSW) typical of a low-income country, the same MSW blended with landfill gas, refuse derived fuel (RDF) made from the same MSW, the same RDF blended with waste oil and a MSW typical of a high-income country. Energy content, the sum of H2 and CO gas percentages, and the ratio of H2 to CO are considered as measures of syngas quality. The simulation shows that landfill gas gives the best results in terms of both H2+CO and H2/CO, and that the MSW of low-income countries can be expected to provide inferior syngas on all three quality measures. Co-gasification of the MSW from low-income countries with landfill gas, and the mixture of waste oil with RDF from low-income MSW are considered as options to improve gas quality.     

Gasification of the char derived from distillation of granulated scrap tyres

This work reports the effect of pressure on the steam/oxygen gasification at 1000 °C of the char derived from low temperature-pressure distillation of granulated scrap tyres (GST). The study was based on the analysis of gas production, carbon conversion, cold gas efficiency and the high heating value (HHV) of the product. For comparison, similar analyses were carried out for the gasification of coals with different rank.In spite of the relatively high ash (≈12 wt.%) and sulphur (≈3 wt.%) contents, the char produced in GST distillation can be regarded as a reasonable solid fuel with a calorific value of 34 MJ kg⁻¹. The combustion properties of the char (E_A ≈ 50 kJ mol⁻¹), its temperature of self-heating (≈264 °C), ignition temperature (≈459 °C) and burn-out temperature (≈676 °C) were found to be similar to those of a semi-anthracite.It is observed that the yield, H₂ and CO contents and HHV of the syngas produced from char gasification increase with pressure. At 0.1 MPa, 4.6 Nm³ kg_char⁻¹ of syngas was produced, containing 28% v/v of H₂ and CO and with a HHV around 3.7 MJ Nm⁻³. At 1.5 MPa, the syngas yield achieved 4.9 Nm³ kg_char⁻¹ with 30% v/v of H₂-CO and HHV of 4.1 MJ Nm⁻³. Carbon conversion significantly increased from 87% at 0.1 MPa to 98% at 1.5 MPa.It is shown that the char derived from distillation of granulated scrap tyres can be further gasified to render a gas of considerable heating value, especially when gasification proceeds at high pressure.     

From feathers to syngas - technologies and devices

The poultry waste produced by industrial slaughterhouses typically contains not only feathers, but also a mixture of animal entrails, nails, blood, beaks and whole carcasses. Economical utilisation of this mixture, varying strongly in composition and moisture content, is, in general, difficult. We demonstrate that this awkward material can be successfully used for gasification in a simple, fixed-bed gasifier. The method of gasification, which we developed, enables control of the gasification process and ensures its stability in the operational regime of a working poultry processing plant. The installation, which has been working in Poland for 2 years, utilises 2 tons of feathers per hour and produces syngas of stable composition and fairly high quality. The syngas is burnt in the combustion chamber adjacent to the gasifier. Heat is recuperated in a boiler producing 3.5 tons per hour of technological steam continuously used for the operation of the slaughterhouse. The whole process complies with the stringent emission standards. In the paper we present the end-use device for feather utilisation and describe the underlying gasification and syngas combustion processes. Key elements of the whole installation are briefly discussed. The environmental impacts of the installation are summarized.     

Gasification characteristics of biomass for tar removal by secondary oxidant injection

Gasification experiments for sawdust were conducted using a fixed bed reactor at 900 °C by varying the secondary oxidant injection ratio to determine the optimal conditions for tar removal along with the enhancement of gasification efficiency. Secondary oxidant was injected as an oxidant at the top zone of the gasifier in varying ratios of 10–30% of the total amount of oxidant. This method was based on the primary method of tar removal and gasification efficiency improvement by thermal cracking of tar. Various gasification performance parameters were evaluated and tar content was estimated by measuring the fluctuation of weight of the activated carbon filter. The results showed that the concentration of tar in the producer gas decreased by injecting the secondary oxidant, even though syngas yield decreased. The recycling potential of the char produced in the gasification experiments was also assessed with the purpose of utilizing char as an adsorbent by determining its surface area and pore volume. The results demonstrated that the char produced from the gasification experiment had similar quality to that of the activated carbon used in this experiment.     

Hydrogen production from food wastes and gas post-treatment by CO2 adsorption

The production of H₂ by biological means, although still far from being a commercially viable proposition, offers great promise for the future. Purification of the biogas obtained may lead to the production of highly concentrated H₂ streams appropriate for industrial application. This research work evaluates the dark fermentation of food wastes and assesses the possibility of adsorbing CO₂ from the gas stream by means of a low cost biomass-based adsorbent. The reactor used was a completely stirred tank reactor run at different hydraulic retention times (HRTs) while the concentration of solids of the feeding stream was kept constant. The results obtained demonstrate that the H₂ yields from the fermentation of food wastes were affected by modifications in the hydraulic retention time (HRT) due to incomplete hydrolysis. The decrease in the duration of fermentation had a negative effect on the conversion of the substrate into soluble products. This resulted in a lower amount of soluble substrate being available for metabolisation by H₂ producing microflora leading to a reduction in specific H₂ production.Adsorption of CO₂ from a gas stream generated from the dark fermentation process was successfully carried out. The data obtained demonstrate that the column filled with biomass-derived activated carbon resulted in a high degree of hydrogen purification. Co-adsorption of H₂S onto the activated carbon also took place, there being no evidence of H₂S present in the bio-H₂ exiting the column. Nevertheless, the concentration of H₂S was very low, and this co-adsorption did not affect the CO₂ capture capacity of the activated carbon.     

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.