Gasification is a process that converts carbonaceous materials, such as coal, petroleum, biofuel, or biomass, into carbon monoxide and hydrogen by reacting the raw material, such as house waste, or compost at high temperatures with a controlled amount of oxygen and/or steam. The resulting gas mixture is called synthesis gas or syngas and is itself a fuel. Gasification is a method for extracting energy from many different types of organic materials.

The advantage of gasification is that using the syngas is potentially more efficient than direct combustion of the original fuel because it can be combusted at higher temperatures or even in fuel cells, so that the thermodynamic upper limit to the efficiency defined by Carnot's rule is higher or not applicable. Syngas may be burned directly in internal combustion engines, used to produce methanol and hydrogen, or converted via the Fischer-Tropsch process into synthetic fuel. Gasification can also begin with materials that are not otherwise useful fuels, such as biomass or organic waste. In addition, the high-temperature combustion refines out corrosive ash elements such as chloride and potassium, allowing clean gas production from otherwise problematic fuels.

Gasification of fossil fuels is currently widely used on industrial scales to generate electricity. However, almost any type of organic material can be used as the raw material for gasification, such as wood, biomass, or even plastic waste.

Gasification relies on chemical processes at elevated temperatures >700°C, which distinguishes it from biological processes such as anaerobic digestion that produce biogas.


 

In a gasifier, the carbonaceous material undergoes several different processes:

Pyrolysis of carbonaceous fuels

Gasification of char

In essence, a limited amount of oxygen or air is introduced into the reactor to allow some of the organic material to be "burned" to produce carbon monoxide and energy, which drives a second reaction that converts further organic material to hydrogen and additional carbon dioxide.

 

The gasification process was originally developed in the 1800s to produce town gas for lighting and cooking. Electricity and natural gas later replaced town gas for these applications, but the gasification process has been utilized for the production of synthetic chemicals and fuels since the 1920s.

Wood gas generators, called Gasogene or Gazogène, were used to power motor vehicles in Europe during World War II fuel shortages.

 

Four types of gasifier are currently available for commercial use: counter-current fixed bed, co-current fixed bed, fluidized bed and entrained flow.
 

The counter-current fixed bed ("up draft") gasifier consists of a fixed bed of carbonaceous fuel (e.g. coal or biomass) through which the "gasification agent" (steam, oxygen and/or air) flows in counter-current configuration. The ash is either removed dry or as a slag. The slagging gasifiers have a lower ratio of steam to carbon  achieving temperatures higher than the ash fusion temperature. The nature of the gasifier means that the fuel must have high mechanical strength and must ideally be non-caking so that it will form a permeable bed, although recent developments have reduced these restrictions to some extent. The throughput for this type of gasifier is relatively low. Thermal efficiency is high as the gas exit temperatures are relatively low. However, this means that tar and methane production is significant at typical operation temperatures, so product gas must be extensively cleaned before use. The tar can be recycled to the reactor.

The co-current fixed bed ("down draft") gasifier is similar to the counter-current type, but the gasification agent gas flows in co-current configuration with the fuel (downwards, hence the name "down draft gasifier"). Heat needs to be added to the upper part of the bed, either by combusting small amounts of the fuel or from external heat sources. The produced gas leaves the gasifier at a high temperature, and most of this heat is often transferred to the gasification agent added in the top of the bed, resulting in an energy efficiency on level with the counter-current type. Since all tars must pass through a hot bed of char in this configuration, tar levels are much lower than the counter-current type.

In the fluidized bed reactor, the fuel is fluidized in oxygen and steam or air. The ash is removed dry or as heavy agglomerates that defluidize. The temperatures are relatively low in dry ash gasifiers, so the fuel must be highly reactive; low-grade coals are particularly suitable. The agglomerating gasifiers have slightly higher temperatures, and are suitable for higher rank coals. Fuel throughput is higher than for the fixed bed, but not as high as for the entrained flow gasifier. The conversion efficiency can be rather low due to elutriation of carbonaceous material. Recycle or subsequent combustion of solids can be used to increase conversion. Fluidized bed gasifiers are most useful for fuels that form highly corrosive ash that would damage the walls of slagging gasifiers. Biomass fuels generally contain high levels of corrosive ash.

In the entrained flow gasifier a dry pulverized solid, an atomized liquid fuel or a fuel slurry is gasified with oxygen (much less frequent: air) in co-current flow. The gasification reactions take place in a dense cloud of very fine particles. Most coals are suitable for this type of gasifier because of the high operating temperatures and because the coal particles are well separated from one another. The high temperatures and pressures also mean that a higher throughput can be achieved, however thermal efficiency is somewhat lower as the gas must be cooled before it can be cleaned with existing technology. The high temperatures also mean that tar and methane are not present in the product gas; however the oxygen requirement is higher than for the other types of gasifiers. All entrained flow gasifiers remove the major part of the ash as a slag as the operating temperature is well above the ash fusion temperature. A smaller fraction of the ash is produced either as a very fine dry fly ash or as a black colored fly ash slurry. Some fuels, in particular certain types of biomasses, can form slag that is corrosive for ceramic inner walls that serve to protect the gasifier outer wall. However some entrained bed type of gasifiers do not possess a ceramic inner wall but have an inner water or steam cooled wall covered with partially solidified slag. These types of gasifiers do not suffer from corrosive slags. Some fuels have ashes with very high ash fusion temperatures. In this case mostly limestone is mixed with the fuel prior to gasification. Addition of a little limestone will usually suffice for the lowering the fusion temperatures. The fuel particles must be much smaller than for other types of gasifiers. This means the fuel must be pulverized, which requires somewhat more energy than for the other types of gasifiers. By far the most energy consumption related to entrained bed gasification is not the milling of the fuel but the production of oxygen used for the gasification.

 

In small business and building applications, where the wood source is sustainable, 250-1000 kWe and new zero carbon biomass gasification plants have been installed in Europe that produce tar free syngas from wood and burn it in a reciprocation engines connected to a generator with heat recovery. This type plant is often referred to as a wood biomass CHP unit but is a plant of seven different processes: biomass processing, fuel delivery, gasification, gas cleaning, waste disposal, electricity generation and heat recovery.

Industrial-scale gasification is currently mostly used to produce electricity from fossil fuels such as coal, where the syngas is burned in a gas turbine.

Gasification technologies have been developed in recent years that use plastic-rich waste as a feed.

Syngas can be used for heat production and for generation of mechanical and electrical power. Like other gaseous fuels, producer gas gives greater control over power levels when compared to solid fuels, leading to more efficient and cleaner operation.

Gasifiers offer a flexible option for thermal applications, as they can be retrofitted into existing gas fueled devices such as ovens, furnaces, boilers, etc., where syngas may replace fossil fuels. Heating values of syngas are generally around 4-10 MJ/m³.

 

 

In principle, gasification can proceed from just about any organic material, including biomass and plastic waste. The resulting syngas can be combusted. Alternatively, if the syngas is clean enough, it may be used for power production in gas engines, gas turbines or even fuel cells, or converted efficiently to dimethyl ether (DME) by methanol dehydration, methane via the Sabatier reaction, or diesel-like synthetic fuel via the Fischer-Tropsch process. In many gasification processes most of the inorganic components of the input material, such as metals and minerals, are retained in the ash. In some gasification processes (slagging gasification) this ash has the form of a glassy solid with low leaching properties, but the net power production in slagging gasification is low (sometimes negative) and costs are higher.

Regardless of the final fuel form, gasification itself and subsequent processing neither directly emits nor traps greenhouse gasses such as carbon dioxide. Power consumption in the gasification and syngas conversion processes may be significant though, and may indirectly cause CO₂ emissions; in slagging and plasma gasification, the electricity consumption may even exceed any power production from the syngas. Combustion of syngas or derived fuels emits the exact same amount of carbon dioxide as would have been emitted from direct combustion of the initial fuel. Biomass gasification and combustion could play a significant role in a renewable energy economy, because biomass production removes the same amount of CO₂ from the atmosphere as is emitted from gasification and combustion. 
 

 

Fluidized bed combustion (FBC) is a combustion technology used in power plants. Fluidized beds suspend solid fuels on upward-blowing jets of air during the combustion process. The result is a turbulent mixing of gas and solids. The tumbling action, much like a bubbling fluid, provides more effective chemical reactions and heat transfer. FBC plants are more flexible than conventional plants in that they can be fired on coal and biomass, among other fuels.

Combustion systems for solid fuels

FBC reduces the amount of sulfur emitted in the form of SO_x emissions. Limestone is used to precipitate out sulfate during combustion, which also allows more efficient heat transfer from the boiler to the apparatus used to capture the heat energy (usually water tubes). The heated precipitate coming in direct contact with the tubes(heating by conduction) increases the efficiency. Since this allows coal plants to burn at cooler temperatures, less NO_x is also emitted. However, burning at low temperatures also causes increased polycyclic aromatic hydrocarbon emissions. FBC boilers can burn fuels other than coal, and the lower temperatures of combustion (800 °C / 1500 °F ) have other added benefits as well.

 

There are two reasons for the rapid increase of fluidized bed combustion (FBC) in combustors. First, the liberty of choice in respect of fuels in general, not only the possibility of using fuels which are difficult to burn using other technologies, is an important advantage of fluidized bed combustion. The second reason, which has become increasingly important, is the possibility of achieving, during combustion, a low emission of nitric oxides and the possibility of removing sulfur in a simple manner by using limestone as bed material.

Fluidized-bed combustion evolved from efforts to find a combustion process able to control pollutant emissions without external emission controls (such as scrubbers). The technology burns fuel at temperatures of 1,400 to 1,700 °F (750-900 °C), well below the threshold where nitrogen oxides form (at approximately 2,500 °F / 1400 °C, the nitrogen and oxygen atoms in the combustion air combine to form nitrogen oxide pollutants). The mixing action of the fluidized bed brings the flue gases into contact with a sulfur-absorbing chemical, such as limestone or dolomite. More than 95% of the sulfur pollutants in coal can be captured inside the boiler by the sorbent. The reductions may be less substantial than they seem, however, as they coincide with dramatic increases in carbon dioxide and polycyclic aromatic hydrocarbons emissions.

Commercial FBC units operate at competitive efficiencies, cost less than today's units, and have NO₂ and SO2 emissions below levels mandated by Federal standards.