TRIVUWAN UNIVERSITY

INSTITUTE OF ENGINEEERING

PURWANCHAL CAMPUS

MODELLING, FABRICATING AND TESTING OF SMALL-SCALE UPDRAFT

GASIFIER USING RICE HUSK

By

DigDarshan Rai (073/BME/011)

Manish Tamang (073/BME/019)

Milan Rimal (073/BME/022)

Misan Limbu (073/ BME/023)

A THESIS SUBMITTED TO THE DEPARTMENT OF MECHANICAL

ENGINEERING IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR

THE DEGREE OF BACHELOR IN MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

DHARAN, NEPAL

Shrawan 28, 2078

 Copyright

The author has agreed that the library, Department of Mechanical Engineering,
Purwanchal Campus, Institute of Engineering may make this thesis freely available for
inspection. Moreover, the author has agreed that permission for extensive copying of
this thesis for scholarly purpose may be granted by the professors who supervised the
work recorded herein or, in their absence, the Head of the Department wherein the thesis
was done. It is understood that the recognition will be given to the author of this thesis
and to the Department of Mechanical Engineering, Purwanchal Campus, and Institute
of Engineering in any use of the material of this thesis. Copying, publication, or the
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use of the material in this thesis in completely or in part should be addressed to:

…………………….

Head of Department

Department of Mechanical Engineering

Purwanchal Campus

Dharan, Nepal
 TRIBHUWAN UNIVERSITY

INSTITUTE OF ENGINEERING

PURWANCHAL CAMPUS

DEPARTMENT OF MECHANICAL ENGINEERING

The undersigned certify that they have read, and recommended to the Institute of
Engineering for acceptance, a thesis entitled " Modelling, Fabricating and Testing of
Small-Scale Updraft Gasifier Using Rice Husk" submitted by Digdarshan Rai, Manish
Tamang, Milan Rimal and Misan Limbu in partial fulfillment of the requirements for
the degree of Bachelor in Mechanical Engineering.

………………

Supervisor,

Er. Keshav Kumar Acharya

Teaching Assistance

……………….

Co-supervisor,

Er. Sujan Dahal

Teaching Assistance

…………………

Head of Department,

Er. Ram Dahal Yadav

Assistance Professor

..…………….

External
 ABSTRACT

Bio gasification technology is one of the prominent technologies for utilizing

agricultural wastes such as rice husk, which is abundant in Nepal. Ergo, this project
deals with modelling, fabricating and testing of fixed-bed Updraft gasifier using rice
husk as feed, having squared shaped reactor, whose dimensions are .14m as width and
.6m as height.

This report outlines design principle of fixed bed updraft gasifier, cyclone separator and
dry filter, and testing methodology of small-scale updraft gasifier. For designing,
different standard parameters were taken from different literature whereas some of them
were assumed. Based on design parameters of small-scale updraft gasifier, gasifier was
fabricated. In addition, fabricated gasifier was tested with 1 kg of rice husk as feed
source, which had been given test results as 18.87 minutes as total operation time, 4.7
kg/hr as Fuel Consumption Rate, 233.4 kg/m2 hr as Specific Gasification Rate, and
thermal efficiency as 7.88%.

This project does not deal with feed source analysis such as Proximate and Ultimate
analysis. Syngas analysis and temperature profile were also not accomplished in this
project.

i
 ACKNOWLEDGEMENT

We would like to appreciate for providing financial support for this project to Institution
of Engineering, Purwanchal Campus, Nepal. In addition, we would like to acknowledge
for providing a platform for this project to Department of Mechanical Engineering,
Purwanchal Campus, Dharan. Acknowledge and thanks are extended to professors,
staffs, and technical assistance provided by Department of Mechanical Engineering
throughout our graduation education.

We express our sincere gratitude to our supervisor, Teaching Assistance Er. Keshav
Kumar Acharya and co- supervisor, Teaching Assistance Er. Sujan Dahal for giving
technical advice, guidance and encourage throughout different stages of this project.
We appreciate our supervisor for providing an opportunity to work with him, we pays
our gratitude for providing his valuable time.

Our Sincere gratitude towards the personnel of Department of Mechanical Engineering

for providing technical support whose skill and knowledge was valuable to this project.

In addition, our personal grateful towards Bhandari Grill House and Technician Shyam
Rai, whose expertise was very useful and valuable for completing this project.

Last but not certainty least, we like to thanks our parent and our well-wisher for
providing financial support, emotional support and for giving encouragement
throughout our graduation education.

ii
 CONTENT

ABSTRACT ................................................................................................ i

ACKNOWLEDGEMENT ..........................................................................ii

LISTS OF TABLES ................................................................................... v

LIST OF FIGURES ................................................................................... vi

LIST OF SYMBOLS .............................................................................. viii

CHAPTER ONE: INTRODUCTION ........................................................ 1

1.1 Background .......................................................................................................... 1
1.1.1 Utilization of rice husk .................................................................................. 2
1.2 Statement of Problem ........................................................................................... 3
1.3 Objective .............................................................................................................. 3
1.2.1Specific objective ........................................................................................... 3
1.3 Scope of Project ................................................................................................... 3
1.4 Limitations of Project ........................................................................................... 3
CHAPTER TWO: LITERSTURE REVIEW ............................................ 4
2.1 Rice Husk ............................................................................................................. 4
2.1.1 Current use of rice husk ................................................................................. 4
2.2 Suitability of Rice Husk for Gasification. ............................................................ 7
2.3 Gasification .......................................................................................................... 8
2.3.1 History of gasification ................................................................................... 8
2.3.2 Gasification chemistry ................................................................................... 9
2.3.3 Gasification technology ............................................................................... 12
2.3.4 Factor affecting gasification ........................................................................ 14
2.4 Cyclone Separator operation .............................................................................. 15
2.5 Dry filter operation ............................................................................................. 17
2.6 Gasifier Design ................................................................................................... 17
2.6.1 Feed source analysis .................................................................................... 17
2.6.2 Rice husk’s heat content .............................................................................. 20
2.6.3 Stoichiometric Air (SA) and Equivalence Ratio (ϵ) .................................... 22
2.6.4 Bulk density of fuel ..................................................................................... 24
2.6.5 Gasifier design ............................................................................................. 25

iii
 2.6.6 Cyclone separator design ............................................................................. 28
2.6.7 Dry filter design ........................................................................................... 30
2.7 Performance Analysis ........................................................................................ 31
2.7.1 Test parameter ............................................................................................. 31
2.8 Some Prior Studies for Fixed-bed Gasification System ..................................... 33
CHAPTER THREE: METHODOLOGY ................................................. 36
3.1 Reviewing of Literature: .................................................................................... 36
3.2 Design Parameters .............................................................................................. 36
3.2.1 Design considerations .................................................................................. 36
3.2.2 Design assumptions: .................................................................................... 37
3.2.3 Design parameter for gasifier ...................................................................... 38
3.2.4 Design parameter for half cyclone filter ...................................................... 41
3.2.5 Design parameter for dry filter system ........................................................ 42
3.3 3D Drawing ........................................................................................................ 42
3.4 Material Selection .............................................................................................. 43
3.5 Fabrication Procedure ........................................................................................ 43
3.6 Testing Procedure:.............................................................................................. 50
CHAPTER FOUR: RESULT AND DISCUSSION ................................. 52
4.1 Result of the Feed Source Analysis: .................................................................. 52
4.2 Result of the Test Parameters for Rice Husk ..................................................... 52
4.3 Result of Syngas Analysis and Temperature Profile .......................................... 53
CHAPTER FIVE: CONCLUSIONS AND RECOMMENDATIONS
.................................................................................................................. 54
5.1 Conclusions ........................................................................................................ 54
5.2 Recommendations: ............................................................................................. 54
REFERENCE ........................................................................................... 56

APPENDIX-I : 2D of Reactor and Insulation ............................................ I

APPENDIX-II: 2D of Char Chamber....................................................... III

APPENDIX-III: 2D of Cyclone Separator ................................................ V

APPENDIX-IV: 2D of Dry Filter........................................................... VII

iv
LISTS OF TABLES

Table 2. 1: Comparison of different types of fixed bed gasifier .................................. 14

Table 2. 2: Respective diameter for required critical particle size .............................. 28
Table 3. 1: Assumptions .............................................................................................. 37
Table 3. 2: Summarized design parameters of gasifier ................................................ 40
Table 3. 3: Summarized design parameters of half cyclone filter ............................... 41
Table 4. 1: Test results ................................................................................................. 52
Table 4. 2: Testing parameter values ........................................................................... 53

v
 LIST OF FIGURES

Figure 1. 1: Utilization of rice husk ............................................................................... 2

Figure 2. 1: Rice husk description ................................................................................. 4
Figure 2. 2: Rice husk in loose form .............................................................................. 5
Figure 2. 3: Rick husk pallets ........................................................................................ 5
Figure 2. 4: Rice husk briquettes ................................................................................... 6
Figure 2. 5: Rice husk ash .............................................................................................. 6
Figure 2. 6: Carbonized rice husk .................................................................................. 7
Figure 2. 7: Temperature profile of updraft gasifier .................................................... 12
Figure 2. 8: Classification of gasifier ........................................................................... 12
Figure 2. 9: Different types of fixed bed gasifier......................................................... 13
Figure 2. 10: Flow diagram of mixture in cyclone separator ....................................... 16
Figure 2. 11: Flow diagram of creeping film flow and secondary flow in cyclone
separator ....................................................................................................................... 16
Figure 2. 12: Bomb Calorimeter .................................................................................. 21
Figure 2. 13: Superficial velocity vs pressure drop graph ........................................... 27
Figure 2. 14: Design dimension of cyclone separator.................................................. 30
Figure 3. 1: (a) 3D view of gasifier and (b) 3D of gasifier with simple filtration system
...................................................................................................................................... 42
Figure 3. 2: [a] 3D of reactor and [b] Section view of reactor..................................... 44
Figure 3. 3: Fabricated reactor ..................................................................................... 44
Figure 3. 4: (a) 3D of char chamber and (b) Section view of char chamber ............... 46
Figure 3. 5: Fabricated char chamber .......................................................................... 46
Figure 3. 6: 3D of grate with grate rod ........................................................................ 47
Figure 3. 7: Fabricated grate mechanism: (a) when open and (b) when close ............. 47
Figure 3. 8: (a) 3D of half cyclone filter and (b) Section view of half cyclone filter .. 48
Figure 3. 9: (a) Section view and (b) 3D of dry filter .................................................. 49
Figure 3. 10: Fabricated gasifier system with insulation ............................................. 49
Figure 3. 11: (a) Filling of rice husk and (b) Ignition flame after starting time .......... 50
Figure 3. 12: Testing .................................................................................................... 51
Figure 3. 13: During testing: (a) boiling testing and (b) bubbling of water................. 51
Figure I. 1: 2D of reactor ................................................................................................I
Figure I. 2: Front view of reactor with insulation ......................................................... II

vi
Figure I. 3: Top view of reactor with insulation ........................................................... II
Figure II. 1: Exploded view of char chamber .............................................................. III
Figure II. 2: Top view of char chamber ....................................................................... III
Figure II. 3: Front view of char chamber .....................................................................IV
Figure III. 1: Front view of half cyclone separator ....................................................... V
Figure III. 2: Top view of half cyclone separator ........................................................VI
Figure IV. 1: 2D of dry filter ..................................................................................... VII

vii
 LIST OF SYMBOLS

Air Flow Rate AFR

Ash A

Inlet pipe content Ae

Content of overflow pipe Ap

Air Density ρair

Bulk Density ρ

Centimeter cm

Combustion Zone Rate CZR

Specific heat of water Cp

Carbon dioxide CO2

Percentage of Carbon present in fuel C

Carbon monoxide CO

Corrections for sulphuric acid Cs

Corrections for nitric acid Cn

Corrections for fuse wire Cf

Corrections for cotton thread Cc

Cone angle Kk

o
Degree Celsius

Dimeter of reactor D

Dimeter of cyclone separator Dc

Diameter of overflow pipe Dp

Diameter of the outlet from the conical Dk

part

viii
Diameter of the filter Dd

Diameter of inlet opening De

Outlet diameter of gasifier Dg

o
Degree

Percent of fixed carbon on a dry, DMMFFC

mineral-matter-free basis

Percent of volatile matter on a dry, DMMFVOL

mineral-matter-free basis

Equivalence Ratio ϵ

Fuel Consumption Rate FCR

Fixed Carbon FC

Food and Agriculture Organization FAO

Gram g

Gasifier efficiency ɳ

Hydrogen H2

Percentage of hydrogen present in fuel H

Height of cylindrical part Hv

Height of conical part Hk

Total height of cyclone Hc

Sink depth of overflow pipe Hp

Inlet opening height He

Overflow pipe overhang below the level Hs

of the lower edge of the inlet pipe

Filter bed height Hf

Height of reactor h

ix
Axial distance of the mouth of the ho
overflow pipe from wall of the separating
cone space

Hour hr

Higher heating value HHV/GHV

Latent heat of water Hfg

Syngas energy content Hv

Kilogram kg

Kilocalorie Kcal

Kilojoule Kj

Kilowatt Kw

Latent heat LH

Lower Heating Value LHV

Distance of the center of gravity of the Le

inlet stream of the mixture into the
separation space

Meter m

Millimeter mm

Megajoule MJ

Mass of water Mw

Mass of air ma

Mass of fuel mf

Mass of product of combustion mpoc

Mass of stoichiometric air (ma)st

Mass of container W

x
Mass of container and sample F

Methane CH4

mass of fuel λ
mass of air

mass of stoichiometric air λst

mass of fuel

Moisture content MC

Moisture content on dry basis MCdry

Moisture content on wet basis MCwet

Mass of water taken W

Nitrogen N2

Nitric acid HNO3

Output power Op

Operating time OT

Oxygen O2

Percentage of oxygen present in fuel O

Product of Combustion POC

Resistance of fuel Rf

Percentage of Sulphur present in fuel S

Sensible heat SH

Specific Gasification Rate SGR

Specific resistance Sr

Starting time ST

Stoichiometric air SA

Sulphuric Acid H2SO4

xi
Retention time Tr

Cooling corrections Tc

Initial temperature of water in T1

calorimeter

Final temperature of water in calorimeter T2

Temperature of water at boiling Tbw

Temperature of water before boiling Ti

Thickness of fuel column Tf

Mixture velocity at the inlet to the ue

cyclone

Velocity of the mixture in the overflow up

pipe at the outlet of the cyclone

Volatile matter VOL/VM

Volume flow rate of cyclone Ve

Velocity of dry filter Vd

Volume of container Vb

Superficial velocity V

New superficial velocity Vnew

Syngas gas flow rate Q

Water equivalent of calorimeter w

Weight of water evaporated We

Weight of the sawdust before drying Wsb

in the oven
Weight of the sawdust after drying in Wsa
the oven

Weight of the sawdust before placing Wssb

xii
on hot plate
Weight of the palm kernel shell after Wssa
heating on the hot plate
Initial weight of the sawdust before Wcb
placing on hot plate
Final weight of the sawdust after Wca
heating on the hot plate
Weight of water evaporated WF
Mass of fuel (solid or liquid) x
Critical particle size X50

xiii
 CHAPTER ONE: INTRODUCTION

1.1 Background
Nepal is one of the countries based on agriculture i.e. Nepal is agricultural country.
Agriculture is central to the national economy. Nearly 80 per cent of households (3.4
million) and 66 per cent of the national labor force depend principally on the sector for
their livelihoods. However, urban-rural disparities are high, and over 80 per cent of
Nepal’s poor people live in rural areas[1].

The country’s agriculture sector is a mix of crop and livestock farming. Although more
than 70 per cent of the workforce is involved in agriculture, the sector generates only
around one third of the country’s Gross Domestic Product[1]. Ergo, production of
different kinds of agriculture product are hugely available due to its fertility land/soil
in every part of country and due to its skilled farmers, which available every region of
country. In this agricultural industry, most successful product is rice, which can be
produced easily in large amount to feed whole population of country. However, this
leads to increase of agricultural waste such as rice husk.

Today world’s energy consumption is mostly based on fuels like petroleum, coal,
natural gas etc., which is ultimately 85% of global energy. Due to increase in
productivity and modernization leads to high rate of fossil fuel depletion, rise in
emission[2].

Some of the most promising, attention-getting energy alternatives are not revolutionary
ideas. Windmills and waterwheels are well known and have been around for centuries.
Today, varieties of improvements, including innovative turbine designs, are
transforming these ancient machines into cutting-edge technologies that can help
nations satisfy their energy needs. There is another old process that is probably not
popular in this part of the world, and may join wind and hydropower in the pantheon of
clean, renewable energy. The process is known as Gasification, a set of chemical
reactions that uses heat and limited oxygen to convert a carbon-containing feedstock
into a synthetic gas, or syngas[3].

Biomass is one of the important sources of renewable energy. By 2050, biomass could
provide nearly 38% of the world’s direct fuel use and 17% of the world’s electricity.
Biomass utilization for energy generation does not make any net addition to the earth’s

1
carbon dioxide levels. When it burns, it releases the carbon dioxide that the plants had
absorbed from the atmosphere recently. One of the attractive technologies for
converting biomass to energy is gasification and the equipment used in gasification
process is referred to as gasifier[4].
1.1.1 Utilization of rice husk
Rice husk was long considered a waste from the rice milling process and was often
dumped and/or burned. But, because it can be easily collected and is cheap, some
amount of rice husk has always been used as an energy source for small applications,
such as for brick production, for steam engines and gasifiers used to power rice mills,
and for generating heat for rice dryers[5]. The high silica content of rice husk ash makes
it a good additive for the steel and concrete industries. To a lesser degree, rice husk ash
is used as soil conditioner, activated carbon, insulator, and others. More recently,
creation of electrical power on a small to medium scale up to 5 megawatts, which has
been piloted throughout Asia, with some promising approaches but also some
demonstrated limits[5]. Failure was mostly due to feedstock supply problems once the
formerly free waste rice husk becomes a traded commodity and due to logistical
problems and the high cost when transport distances become too large. A diagram of
rice husk use is shown in figure below[5]:

Figure 1. 1: Utilization of rice husk

Source: (Rice husk n.d.)

2
1.2 Statement of Problem
Since our country is least developed country; thus, leads to less advancement of
infrastructure of country, which ultimately leads to shortage of energy. In addition, our
country is agricultural country; so, our project had been conducted to increase energy
using agricultural waste like Rice husk etc.
1.3 Objective
Main objective of this project is to design, develop and test the scale-small updraft
gasifier using rice husk.

1.2.1Specific objective
This project gives other specific objectives, which are as follows:

a) To design and fabricate the small scale updraft gasifier

b) To find Fuel Consumption Rate (FCR) and Specific Gasification Rate (SGR).
c) To find Operating Time and thermal efficiency.
d) To design simple filtering system.

1.3 Scope of Project

This project have following as scope:

a) This project deals with designing, developing and testing of scale-small updraft
gasifier using rice husk as fuel source.
b) This project deals with study on the suitability of Rice Husk as fuel source.

1.4 Limitations of Project

Due to different circumstances, following limitations had found as:

a) This project does not deal with fuel source analysis, syngas analysis and
temperature profile.
b) This project does not deal with fabricating and testing of filtering system.

3
 CHAPTER TWO: LITERSTURE REVIEW

2.1 Rice Husk

Rice husk sometimes called as Rice hull is coating on seed of rice grain, which includes
silica and lignin to protect rice grain during growing season. Each kg of milled white
rice results in roughly 0.28 kg of rice husk as a by-product of rice production during
milling. Comparison of characteristic of rice husk with other solid fuels can be
summarized as follows as[6]:

a) Its high silica content causes excessive wear to parts of processing machines, such
as conveyors or grinders, and hampers digestibility in livestock.
b) The content of volatile matter in the rice husk is higher than in wood and much
higher than in coal whereas, fixed carbon is much lower than in coal. Ash content
in the rice husk is much higher than in wood and coal, which causes barriers in
energy conversion.
c) The high content of ash, alkali, and potassium causes agglomeration, fouling, and
melting of the parts of combustors or boilers.

Figure 2. 1: Rice husk description

Source: (Rice husk n.d.)

2.1.1 Current use of rice husk

Uses of Rice husk can be explained according to its form, which are listed as below:

4
Rice husk in its loose form is mostly used for energy generation such as Combustion
and Gasification. Combustion is the process of burning carbon in the rice husk, which
emits CO2 and generates heat energy for further use. One of the most efficient uses of
this by-product is its direct combustion without the need for a heat exchanger with a
proper furnace to generate heat for drying paddy. Gasification is the process of
converting rice husk to synthesis gas (syngas) in a gasifier reactor with a controlled
amount of air. Syngas can be used as fuel for drying and cooking or in a cogeneration
system to produce electricity[6].

Figure 2. 2: Rice husk in loose form

Source: (Rice husk n.d.)

Rice husk briquettes and pellets are produced using densification to increase the density
of materials and their combustion performance. These densified rice husks are mainly
used in industrial boilers as a substitute for fossil fuel[6] .

Figure 2. 3: Rick husk pallets

Source: (Rice husk n.d.)

5
 Figure 2. 4: Rice husk briquettes

Source: (Rice husk n.d.)

Rice husk ash is the remaining by-product after combustion is done. The amount of
carbon remaining in ash depends on the combustion performance (i.e., complete or
incomplete combustion). Rice husk ash can be used as a soil amendment and as additive
in cement and steel, among others. However, only small amounts compared to the total
rice husk production are used for such purposes[6].

Figure 2. 5: Rice husk ash

Source: (Rice husk n.d.)

Carbonized rice husk is produced by thermal decomposition of the rice husk under a
limited supply of oxygen and at relatively low temperatures (less than 700°C). Bio char
produced from carbonization can be used as soil amendment, for processing fertilizer,
and as activated carbon, etc.[6].

6
 Figure 2. 6: Carbonized rice husk

Source: (Rice husk n.d.)

2.2 Suitability of Rice Husk for Gasification.

Some of prior studies, which are listed below show its suitability:

(Belonio 2005) had conducted theoretically and experimentally investigation on Top

Lit downdraft gasifier modifying it to gas stove using freshly obtained rice husk as fuel.
After several tests, he concluded that with the aid of rice husk having moisture content
as 10-20%, ash content as 15-21%, bulk density 100-120 kg/m3 and 3000kcal/hr as low
heating value, gasifier-having dimension 0.15m as diameter and 0.6 m as height of
reactor, whose efficiency was found 55.8-66.5% with 900-1000 oc as operating
temperature[7].

(Sarkar 2012) had investigated theoretically and experimentally updraft gasifier with
fuel source as rice husk. Ergo, the result of his investigation as rice husk’s moisture
content was 8.95 %, bulk density 100.03 kg/m3, volatile matter content 65%, fixed
carbon content 10% and ash content 25%. After fabrication and simultaneously
performance testing, his design was able to produce combustible syngas having CO-
20.62%, H2 - 10.62%, CO2 - 13.61%, CH4 - Up to 4%, N2 - 52.62%[8].

(Htet 2018) had developed open core downdraft gasifier theoretically and
experimentally for YSD2100 Diesel Engine having reactor diameter as 35.6cm, height
of reactor as 61cm, gasifier efficiency as 50% and output power as 14 Kw using Rice
husk as fuel source[9].
(Breault 2010) had experimentally investigated at 800 oC using Downdraft Gasifier
technology, where fuel source as coconut shell, rice husk and groundnut shell, ergo,

7
production of combustible gas was achieved. However, based on performance these
three agricultural waste, coconut shell was most suitable for gasification[10].

2.3 Gasification
Gasification is a process that coverts biomass- or fossil fuel- based carbonaceous
materials into gases including as the largest fractions: nitrogen, carbon monoxide,
hydrogen, and carbon dioxide. This is achieved by reacting the feedstock material at
high temperatures (typically >700 °C), without combustion, via controlling the amount
of oxygen and/or steam present in the reaction. The resulting gas mixture called as
syngas (from synthesis gas) or producer gas and is itself a fuel due to the flammability
of the H2 and CO of which the gas is largely composed [5]. The production of these
gases is by reaction of water vapor and carbon dioxide through a glowing layer of
charcoal. Ergo, the key to gasifier design is to create conditions such that a) biomass is
reduced to charcoal and, b) charcoal is converted at suitable temperature to produce CO
and H2[8].

Rice husk gasification is the process of converting rice husks fuel into combustible
carbon monoxide by thermo-chemical reaction of the oxygen in the air and the carbon
available in this material husk during combustion. In complete combustion of fuel, the
process takes place with excess air. In gasification process, on the other hand, it is
accomplished with excess carbon. In order to gasify rice husks, about 30 to 40% of the
stoichiometric air (4.7kg of air per kg of rice husk) is needed[7].
2.3.1 History of gasification
Energy has been produced at industrial scale via gasification since the early 19th
century. Initially coal and peat were gasified to produce town gas for lighting and
cooking, with the first public street lighting installed in Pall Mall, London on January
28, 1807, spreading shortly to supply commercial gas lighting to most industrialized
cities until the end of the 19th century[11]when it was replaced with electrical lighting.
Gasification and syngas continued to be used in blast furnaces and more significantly
in the production of synthetic chemicals where it has been in use since the 1920s[5].
Wood gas generators, called Gasogene or Gazogène, were used to power motor vehicles
in Europe. By 1945, there were trucks, buses and agricultural machines that were
powered by gasification. It is estimated that there were close to 9,000,000 vehicles
running on producer gas all over the world[5].

8
In addition to reducing dependence on petroleum, gasification has been studied recently
as a value-added process of by land filling, incineration, or microbial decomposition
could be gasifies as alternative process to traditional disposal methods, which are
sometimes unavailable, expensive or cumbersome[12].

2.3.2 Gasification chemistry

According to (Gasification n.d.), inside gasifier, following thermos-chemical reactions
occurs and can be explained properly as below steps[5]:

a) Dehydration or drying process:

This process occurs at around 100 °C. Where, the resulting steam is mixed into the gas
flow and may be involved with subsequent chemical reactions, notably the water-gas
reaction if the temperature is sufficiently high.

b) Pyrolysis (or devolatilization) process

This process occurs at around 200–300 °C. In this process, volatiles are released
and char is produced, resulting in up to 70% weight loss for coal. The process is
dependent on the properties of the carbonaceous material and determines the structure
and composition of the char, which will then undergo gasification reactions

c) Combustion process
This process occurs as the volatile products and some of the char primarily reacts
with oxygen to form carbon dioxide and small amounts of carbon monoxide, which
provides heat for subsequent gasification reactions. Letting C represent a carbon
containing organic compound, the basic reaction here is

C + O2 CO2

d) Gasification process

This process occurs as the char reacts with steam and carbon dioxide to produce carbon
monoxide and hydrogen, via two reactions

First as C+H2O H2+CO

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

9
carbon dioxide. Further reactions occur when the formed carbon monoxide and
residual water from the organic material react to form methane and excess carbon
dioxide.
4CO+2H2O CH4+3CO2

Second as C+CO2 2CO

This reaction occurs more abundantly in reactors that increase the residence time of the
reactive gases and organic materials, as well as heat and pressure. Catalysts are used in
more sophisticated reactors to improve reaction rates, thus moving the system closer to
the reaction equilibrium for a fixed residence time.

e) Reversible process:

In addition, the reversible gas phase water-gas shift reaction reaches equilibrium very
fast at the temperatures in a gasifier. This balances the concentrations of carbon
monoxide, steam, carbon dioxide and hydrogen.

CO+H2O CO2+H2

From (Belonio 2005) [7],

Gasification of rice husks is accomplished in an air-sealed chamber, known as the

reactor. A fan into the fuel column to convert rice husks into carbon-rich char so that
by thermo-chemical reaction it would produce carbon monoxide, hydrogen, and
methane gases, which are combustible when ignited, introduces limited amount of air.
The gas produced during gasification is composed of: (a) carbon monoxide, (b)
hydrogen, (c) methane, (d) carbon dioxide, and (e) water vapor. The chemistry of
gasification and the reactions of gases during the process are illustrated below:

1) Combustion C + O2 = CO2
2) Water Gas C + H2O = CO + H2
3) Water Shift Reaction CO + H2O = CO2 + H2
4) Boudouard Reaction C + CO2 = 2 CO
5) Methane Reaction C + 2 H2 = CH4
Carbon monoxide, hydrogen, and methane are combustible gases while the carbon
dioxide and vapor are not. Some reports claim that there is nitrogen gas in trace amount
during gasification of rice husks.

10
Again, (Sarkar 2012) gives detail about thermochemical reaction inside updraft gasifier,
which is listed below[8]:

a) Combustion Zone

The combustible substance of a solid fuel is usually composed of elements carbon,

hydrogen and oxygen. In complete combustion, carbon dioxide is obtained from carbon
in fuel and water is obtained from the hydrogen, usually as steam. The combustion
reaction is exothermic and yields a theoretical oxidation temperature of 14500 C. The
main reactions, therefore, are:
1. C + O2 = CO2 (+ 393 MJ/kg mole)
2. 2H2 + O2 = 2H2O (- 242 MJ/kg mole)

b) Reduction Zone
The products of partial combustion (water, carbon dioxide and residues partially
cracked pyrolysis products) now pass through a red-hot charcoal bed where the
following reduction reactions take place.
1. C + CO2 = 2CO (- 164.9 MJ/kg mole)……………………. (3)
2. C + H2O = CO + H2 (- 122.6 MJ/kg mole)……………….. (4)
3. CO + H2O = CO2 + H2 (+ 42 MJ/kg mole)
4. C + 2H2 = CH4 (+ 75 MJ/kg mole)
5. CO2 + H2 = CO + H2O (- 42.3 MJ/kg mole)
Reactions (3) and (4) are main reduction reactions and being endothermic have the
capability of reducing gas temperature. Consequently, the temperatures in the reduction
zone are normally 800-1000oC. Lower the reduction zone temperature (~ 700-800 oC),
lower is the calorific value of gas.
c) Pyrolysis Zone
Wood pyrolysis is an intricate process, which is not still completely understood. The
products depend upon temperature, pressure, residence time and heat losses. However,
following general remarks can be made about them.
Up to the temperature of 200 0C only water is driven off. Between 200 to 2800C, carbon
dioxide, acetic acid and water are given off. The real pyrolysis, which takes place
between 280 to 500 0C, produces large quantities of tar and gases containing carbon
dioxide. Besides light tars, some methyl alcohol is also formed. Between 500 to 700 0C
the gas production is small and contains hydrogen.

11
 Figure 2. 7: Temperature profile of updraft gasifier

Source: (Sarkar 2012)

2.3.3 Gasification technology

Gasification system is broadly divided into fixed-bed type, fluidized-bed type and
entrained flow type. However, latest invention was plasma type gasification system.
Fluidized-bed type biomass gasification is suitable for large-scale project, whereas
fixed bed type biomass gasification systems are suitable for small-scale project. Only
fixed-bed type biomass gasification systems were reviewed due to its relatively
simplicity in designing step[5].

Figure 2. 8: Classification of gasifier

According to (G Suresh Kumar 2018)[13], Fixed-bed type systems depends upon

direction of air flow, which are listed below:

12
1. Downdraft
2. Updraft
3. Cross draft

Downdraft gasification is also called co-current gasification. In this gasification, air is

introduced at the center portion of the reactor and gas is drawn from the downside. The
oxidation and reduction zones will be just below the point of air inlet. Even though its
overall efficiency is relatively less than updraft gasifier, it has a lesser tar forming
tendency and higher gas loading capacity. Downdraft gasifiers are further divided into
throated (Imbert type) and throat less (Open core)[13].

Updraft gasification is the oldest and simplest type of gasification. It is also known as
counter-current or counter-flow gasification. Feedstock is introduced at the top of the
gasifier while air intake is at the bottom. Syngas leaves at the top of the gasifier. The
updraft gasifier offers these advantages: Proven technology, low cost process, able to
handle high moisture and high inorganic content (e.g., municipal solid waste), Low gas
exit temperatures and high equipment efficiency[8].
Cross draft gasification system, have similar reactor like updraft gasifier reactor i.e. fuel
will enter from top and thermochemical reaction will occur progressively as this fuel
descends into reactor. Ergo, difference between them is that air will be entering the
gasifiers from the side of the reactor, rather than from top or bottom[8].

Figure 2. 9: Different types of fixed bed gasifier

Source: (Sarkar 2012)

Ergo, advantages and disadvantage over each other is explained in below table:

13
 Table 2. 1: Comparison of different types of fixed bed gasifier

Source: (Sarkar 2012)

S.N Gasifier Merits Demerits

1 Updraft gasification Small pressure drop Great sensitivity to tar
Good thermal and moisture content
efficiency of fuel
Little tendency Relatively long time
towards slag required for startup of
formation IC engine
Poor reaction capability
with heavy gas load
2 Downdraft gasification Flexible adaptation of Design tends to be tall
gas production to load Not feasible for very
Low sensitivity to small particle size of
charcoal fuel
Dust and tar content of
fuel
3 Cross draft gasification Short design height Very high sensitivity to
Very fast response time slag formation
to load High pressure drop
Flexible gas production

2.3.4 Factor affecting gasification

(Belonio 2005) had investigated experimentally rice husk Top lit updraft type gas stove
with different design criteria and different criteria of input parameters. Ergo, literature
(Belonio 2005) concluded that factors, which affects the gasification, are as follows[7]:

1. Energy Content of Fuel

Higher fuel energy content, will be higher influence for gasification, when using rice
husks that are freshly obtained from the rice mill. However, Deteriorated rice husks,
such as those dumped on roadsides and along riverbanks for several months, were
observed to be more difficult to gasify than the fresh ones.
2. Fuel Moisture Content

14
Lower the moisture content, more influence towards gasifier. Freshly produced rice
husks are preferred to use for they usually contains only 10 to 12% moisture. Rice husks
with high moisture content should be dried first before they are used as fuel for the
gasifier.
3. Size and Form of Fuel
Rice husks obtained from steel huller type rice mill or “kiskisan” are difficult to gasify.
Over milling of rice produces powdery-form rice husks, which require high-pressure
fan in order to be gasified. Rice husks produced from rubber roll-type rice mill are
more suitable for gasifier operation.
4. Size Distribution of the Fuel
Rice husks mixed with other solid fuels are not suitable for gasifier operation. Not
uniform fuel size distribution will result to difficulty in getting well-carbonized rice
husks, which affects fuel gasification.

5. Temperature of the Reactor

Temperature of the reactor during gasification also affects the production of flammable
gas. There is a need to properly insulate the reactor so that during gasification,
flammable gas can be produced. Rice husk ash and refractory materials are good
examples of materials effective in maintaining high temperature in the reactor for better
gasification. Providing an annular space in a double core reactor is also an effective
way in maintaining high temperature in the reactor.

2.4 Cyclone Separator operation

The compressed humid air flows either axially or tangential inlet to a cyclone of
velocity. The air flows in a circular way track respective a helix of radius where
centrifugal acceleration acts on the particles. Thanks by centrifugal forces are particles
trapped on the pf the cyclone. Particles under the action gravitational forces fall into the
collecting part of the cyclone, from where they are discharged by other mechanisms
outside the collection area. Thus, separated air from particle-laden gas then, flows
through the outlet of the system[15].

15
 Figure 2. 10: Flow diagram of mixture in cyclone
separator

Source: (MIČEK 2015)

In addition to the helical flow in the cyclone, there are two other types of flow near the
inlet. It is creeping film stream and secondary film stream, which are available but
undesirable. These currents only exist in the case of cyclone with an overflow pipe and
are shown in figure aside[15]:

Figure 2. 11: Flow diagram of creeping film flow and

secondary flow in cyclone separator

Source: (MIČEK 2015)

16
2.5 Dry filter operation
Particle-laden gas is introduced towards filtering material, where gas and contaminated
particle are captured by filter material along its bed height. Ergo, results in separation
of contaminated particle from particle- laden gas.
2.6 Gasifier Design
Design calculation means determine reactor dimensions, airflow requirement, and feed
material properties.

2.6.1 Feed source analysis

For feed source analysis, proximate an ultimate analysis should be done for calculation
of feed heat content, stoichiometric air and equivalence ratio.

Proximate analysis of rice husk

The "proximate" analysis gives moisture content, volatile content (when heated to
600“C), the free carbon remaining at that point, the ash (mineral) in the sample and
the high heating value (HHV) based on the complete combustion of the sample to
carbon dioxide and liquid water. The low heating value, LHV, gives the heat released
when the hydrogen is burned to gaseous water, corresponding to most treating
applications and can be calculated from the HHV and H2 traction[3].

The quality of the fuels was tested following the America Society for Testing
Materials. These tests included: Moisture content, Volatile and Fixed carbon, and
Ash content[3].
The procedure and methods employed while conducting each of these tests are:
Moisture content:
The heating value of the gas produced by any type of gasifier depends at least in
part on the moisture content of the feedstock. Moisture content can be determined
on a dry basis as well as on a wet basis[3].
Accurately measured fuel samples should be dried in an electric oven at a
temperature of 105oC for one hour. In this way, following data should be taken,
which is shown below and should be calculated according to equation [2.1] and
[2.2]:

Wsb = Weight of the sample before drying in the oven

Wsa = Weight of the sample after drying in the oven

The moisture content on the wet basis is defined as

17
 Wsb - Wsa
MCwet = ×100………………………………equation [2.1]
Wsb

The moisture content on the dry basis is defined as

100 × MCwet
MCdry = 100 + MC …………………………………….equation [2.1]
wet

According to the FAO, high moisture contents reduce the thermal efficiency since
heat is used to drive off the water and consequently this energy is not available for
the reduction reactions and for converting thermal energy into chemical bound
energy in the gas. Therefore, high moisture contents result in low gas heating
values. When the gas is used for direct combustion purposes, low heating values
can be tolerated and the use of feedstock with moisture contents (dry basis) of up
to 40 - 50 percent is feasible, especially when using updraft gasifiers[3].

Volatile Content:

For determining of volatile content, fuel samples were crushed to powdered form,
crushed samples was place in different porcelain crucibles. They were each covered
with a lid with little opening left and placed on hot plates at a temperature of 500
o
C – 600oC to drive off the volatiles. The heating continued until the flame coming
out through the holes have ceased. This indicates that all volatile matter has been
driven off. After this, the weight of each of the heated samples was taken[3]. Now,
in following way data should be taken and calculated according to equation [2.3]

Wssb = Weight of the sample before placing on hot plate

Wssa = Weight of the sample after heating on the hot plate

The volatile content = Wssb - Wssa

Wssb - W ssa
Percentage of volatile content = ×100 volatile matter by
Wssb

weight………………………………………equation [2.3]
Ash Content:
For ash content test, fuel samples were carried out by crushing the samples and
accurately weighed samples in a porcelain crucible with a lid. The samples were
heated to temperature of 500 oC – 600oC on hot plate. After two hours, the weight
of the samples was taken. Similarly, in following ways data should be taken ,which
is listed below and should be calculated by formula in equation[2.4] [3]:
Wcb = Initial weight of sample before placing on hot plate

18
Wca = Final weight of the sample after heating on the hot plate
Wcb - Wca
The ash content of the sawdust = 100 - ×100… equation [2.4]
Wcb

Fixed Carbon
The value of the fixed carbon is calculated as follows[3]:

%FC = 100 — (%Moisture + % volatility + % ash)………… equation [2.5]

Ultimate analysis
The "ultimate" analysis" gives the composition of the feed source in wt% of carbon,
hydrogen and oxygen (the major components) as well as sulphur and nitrogen[3].
In the following ways:
Calculation of the percent fixed carbon on a dry, mineral-matter-free basis[3]:
FC
DMMFFC = FC + VOL ×100 …...equation [2.6]

Where:
DMMFFC = dry mineral – matter - free fixed carbon (% by weight)
FC = fixed carbon, from fuel analysis (% by weight)
VOL = volatile matter, from fuel analysis (% by weight)
Calculation of the percentage of volatile matter on dry, mineral-matter
basis[3]:
VOL
DMMFVOL = FC + VOL ×100 …………… equation [2.7]

Where:
DMMFVOL = dry mineral -matter - free volatile matter (% by weight)
FC = fixed carbon, from fuel analysis (% by weight)
VOL = volatile matter, from fuel analysis (% by weight)
Calculation of the weight percent of carbon in the fuel[3]:
DMMFFC + 0.9(DMMFVOL - 14) × (VOL ×FC)
C= ……………equation[2.8]
100

Where:
C = elemental carbon in the fuel (%by weight)
DMMFVOL = dry mineral - matter - free volatile matter (% by weight)
FC = fixed carbon, from fuel analysis (% by weight)
VOL = volatile matter, from fuel analysis (% by weight)
DMMFFC = dry mineral - matter - free fixed carbon (% by weight)

19
Calculation of weight percent of nitrogen in the fuel[3]:
(2.1 - 0.012DMMFVOL) × (VOL × FC)
N2 = ………… equation [2.9]
100

Where:
N2 = elemental nitrogen in fuel (% by weight)
DMMFVOL = dry mineral - matter -free volatile matter (% by weight)
FC = fixed carbon, from fuel analysis (% by weight)
VOL = volatile matter, from fuel analysis (% by weight)
Calculation of weight percent of hydrogen in the fuel [3]:
DMMFVOL × 7.35
(( ) - .013) × (VOL × FC)
DMMFVOL + 10
H2 = ………… equation [2.10]
100

Where:
H2 = elemental hydrogen in fuel (%by weight)
DMMFVOL = dry mineral - matter - free volatile matter (% by weight)
FC = fixed carbon, from fuel analysis (% by weight)
VOL = volatile matter, from fuel analysis (% by weight)
Calculation of weight percent of oxygen on the fuel[3]:
O2 = 100 - Ash - S - H2 – C - Moisture- N2………………equation [2.11]
Where
O2= elemental oxygen in fuel (% by weight)
S = elemental Sulphur in fuel = 0
Ash = ash content
Moisture = moisture content
2.6.2 Rice husk’s heat content
Calorific value of rice husk is important factor in design. Ergo, for determination of
calorific value, two methods are available, which are as follows:

Bomb Calorimeter
Bomb calorimeter is used to determine calorific value of solid and liquid fuels
experimentally. A bomb calorimeter contains a cylindrical bomb made by stainless
steel. Combustion takes place in this cylinder. The lid contains two stainless steel
electrodes. Oxygen is supplied through oxygen valve for combustion. The electrode
attached with a small ring, which supports nickel or stainless steel made crucible. The

20
bomb is taken in a copper calorimeter, which is surrounded by air and water jacket in
order to prevent heat loss by radiation. The copper calorimeter also contains electrically
operated stirrer and Beckmann’s thermometer (take reading with temperature
difference up to 0.01oC[14].

Working: In a crucible, a known amount of the fuel is placed in the nickel or stainless
steel crucible, which is supported by a ring. A fine magnesium wire touches the fuel
sample, which is already connected to the electrodes. The bomb lid is lightly screwed
and filled with oxygen at about 25 atm pressure, is placed in copper calorimeter
containing a known amount of water. The electrically operated stirrer is driven and
notes the initial temperature of water. After that, both the electrodes are connected to a
battery to complete the circuit. The fuel sample is burn and heat is liberated. To
maintain the uniform temperature, water is continuously stirred and the final
temperature of water is noted[14].

Figure 2. 12: Bomb Calorimeter

Source: (Singh n.d.)

Calculation[14]:

Mass of fuel (solid or liquid) =xg

Mass of water taken =Wg
Water equivalent of calorimeter =wg
Initial temperature of water in = T1 K
calorimeter

21
 Final temperature of water in calorimeter = T2 K
High or gross calorific value (HHV) = (W + w) (T2 - T1) (x) cal/g………… equation
[2.12]
LHV = HHV – H/100 × 𝟗 × 587 kcal/kg … equation [2.13]
Where:
H = percentage of hydrogen in fuel
Correction[14]:
HHV or GHV = (W + w) (T2 - T1 - Tc) (Cs + Cn + Cf + Cc)…………….equation [2.14]
Where
Tc = cooling corrections
Cs = Corrections for sulphuric acid (H2SO4)
Cn = Corrections for nitric acid (HNO3)
Cf = Corrections for fuse wire
Cc = Corrections for cotton thread
Dulong’s formula:
This method can only give approximation value based on the percentage of constituents
(C, H, O and S) present in fuel. Mathematically,

O
Higher Heating Value (HHV) = 1/100(8080C + 34500 (H - 8 ) + 2240S) Kcal/kg …

equation [2.15]

9
Lower Heating Value (LLV) = HHV - 100 H × 587 Kcal/kg …...equation [xvi]

Where, C, H, O and S are percentage of carbon, hydrogen, oxygen and Sulphur present
in fuel[14].

2.6.3 Stoichiometric Air (SA) and Equivalence Ratio (ϵ)

Theoretically, complete combustion can be obtained when stoichiometric amount of air
used. Stoichiometric amount (also termed theoretical air or air for complete
combustion) of air can be calculated by considering the products of combustion
obtained on complete combustion. In general any balanced chemical equation (mole
input = moles output) can be used to calculate stoichiometric amount of air[8].
Way of finding SA:
Combustion is a fast chemical reaction between combustible component(s) and an
oxidizing agent. Mostly air is used for combustion. Dry air contains 21% O2 and 79%

22
N2 and so 1 mole of O2 carries with it 3.76 moles of N2. Combustion equations with air,
when complete combustion takes place are[8]:
C+ (O2+3.76N2) = CO2+3.76N2…………….. (A)
S+ (O2+3.76N2) = SO2 + 3.76N2…………….. (B)
H2 + ½(O2+3.76N2) = H2O + 1.88N2…………… (C)
CH4 + 2(O2+3.76N2) = CO2 + 2H2O + 7.52N2… (D)
In combustion equations A to D, we note that 1mole of C requires 1 mole of O2 or 4.76
moles of air to give 1 mole of CO2 and 3.76 moles of N2. Similarly, 1 mole of H2
requires mole of O2 or 2.38 moles of air to give 1 mole H2O and 1.88 mole of N2.
Let us calculate stoichiometric amount of air for combustion of rice husk of
composition of C=48.88%, H=5.52%, O=44%, 10% moisture content per kg of rice
husk[8].
C= = 4.07, H= = 5, O= = 2.75 12 8 .4815 16 44
Chemical formula = C4.07H5O2.75 = C8H10O5
Total weight = (12 × 8 + 10 +16 × 5) = 186
Chemical reaction with air for complete combustion of rice husk[8]
Complete combustion
3(C8H10O5 + H2O) + 24(O2 + 3.78N2) 24CO2 + 18H2O +24 ×
3.78 N2
Weight of husk = 186 × 3 = 558 unit
Weight of air = 24 (32 + 3.78 × 28) = 3308.16
Air: Husk =3308: 558 = 5.93: 1
For complete combustion of 6.3 kg of rice husk, the amount of air would be 5.93 × 6.3
= 37.35 kg[8]
Actual amount of air supplied for gasification[8]
Diameter of inlet pipe = 1 inch = (0.0254)2 m
Velocity of air, V =4.5 m/s
Therefore, Area of the inlet pipe, A =4π (0.0254)2 = 5.067×10-4 m2
Therefore, quantity of air supplied, Q = AV = 4.5×5.067×10-4 = 2.28 ×10-3 m3/s
= 2.28 ×10-3 × 3600
= 8.20 m3/hr
Quantity of rice husk per batch = 6.3 kg
Total running time = 1 hr
Air supplied for gasification = 8.20 × 1 = 8.20 m3

23
We know that density of air is 1.2 kg/ m3
Amount of air supplied = 8.20 × 1.2 = 9.84 kg
Stoichiometric amount of air required for 6.3 kg rice husk = 37.35 kg[8]
For a given type of fuel, air fuel ratio controls the combustion and amount of products
of combustion (POC) [8]
Consider combustion of fuel of amount mf with air ma, which produces POC mpoc
mf + ma = mpoc[8]
mpoc ma
=1 + …………………… equation [2.16]
mf mf

mass of fuel (mf )

Let, = [8]
mass of air (ma)
(ma)st
λst = stoichiometric ratio of when mf is contant
mf

Therefore,
 λst = ϵ;(ma)st is mass of stoichiometric air
mpoc
= 1 + ϵλst
mf

From the above calculation

Equivalence ratio, (ϵ) = 9.84/ 37.35 = 0.27[8]
Here, ϵ < 1 which means < λst or ma < (ma)st this situation leads to incomplete
combustion. POC will contain CO, smoke dust besides CO2, N2 etc.
2.6.4 Bulk density of fuel
The bulk densities of samples were determined by cylindrical container, which is best
suited the quantities of test samples available were chosen. To determine the volume of
a test container, the pre-weighed container was filled with water (at room temperature)
until maximum capacity. The mass of water plus the container was measured. The
volume of the container was calculated from the net weight of water and the density of
water (1000 kg/m3) [8].
A pre-weighed cylindrical was filled with test sample (Size 1 cm, except rice husk) and
dropped from a height of 15 cm on to a horizontal wooden surface. The sample material
in the container was topped until the maximum capacity was reached. Surplus material
was leveled off with a wooden scantling and pieces, which extended above the top of
the cylinder, were sheared off with a pair of garden shears before weighing, instead of
pulling them out and refilling until maximum capacity. The container and sample were
weighed, and net mass of material was divided by the volume of container to obtain the
bulk density as follows[8] :

24
 F-W
ρ= …………….equation [2.17]
Vb

Where:
ρ = bulk density
F = mass of container and sample
W = mass of container
Vb = volume of container
2.6.5 Gasifier design
Now, some important parameters that need to be considered in determining the
appropriate size of the rice husk gasifier, taking into consideration the power output
desired. The size of the gasifier can be easily estimated by computing these
parameters[7]. Ergo, such parameters are as follows:
Energy Input

This refers to the amount of energy needed in terms of fuel to be fed into the stove. This
can be computed using the formula[7]:

1
Fuel Consumption Rate (FCR) = Op× LHV×ɳ……………… equation [2.18]

Where:
FCR - Fuel Consumption Fate, kg/hr
Op - heat energy needed, Kcal/hr
LHV - heating value of fuel, Kcal/kg
ɳ - Gasifier efficiency
Reactor Diameter

This refers to the size of the reactor in terms of the diameter of the cross-section of the
cylinder where rice husks are being burned. This is a function of the amount of the fuel
consumed per unit time (FCR) to the specific gasification rate (SGR) of rice husks,
which is in the range of 110 to 210 kg/m2-hr. As shown below, the reactor diameter can
be computed using the formula[7]:
√1.27FCR
Diameter (D) = …………………… equation [2.19]
√SGR

Where:
D - Diameter of reactor, m
FCR - Fuel Consumption Rate, kg/hr
SGR - Specific Gasification Rate of rice husk, kg/m2-hr

25
Due to difficult in fabrication and other factor, new alternation was made, which is
shown as below[3]:
πD2
Area of reactor = = L2 ………… equation [2.20]
4

Height of the Reactor

This refers to the total distance from the top and the bottom end of the reactor. This
how long would the stove be operated in one loading of fuel. It is a function of a number
of variables such as the required time to operate the gasifier (T), the specific gasification
rate (SGR), and the density of rice husks (ρ). As shown below, the height of reactor can
be computed using the formula[7],
SGR
Height of parameter (h) = T × …………… equation [2.21]
ρ

Where:
h- Height of the reactor, m
SGR - Specific gasification rate of rice husk, kg/m2-hr
T - Time required to consume rice husk, hr
ρ - Rice husk density, kg/m3
Amount of Air Needed for Gasification
This refers to the rate of flow of air needed to gasify rice husks. This is very important
in determining the size of the fan or of the blower needed for the reactor in gasifying
rice husks. As shown, this can be simply determined using the rate of consumption of
rice husk fuel (FCR), the stoichiometric air of rice husk (SA), and the recommended
equivalence ratio (ϵ) for gasifying rice husk of 0.3 to 0.4. As shown, this can be
computed using the formula[7],
ϵ × FCR× SA
Airflow rate (AFR) = ……………. Equation [2.22]
ρair

Where:
AFR - Airflow rate, m3/hr
ϵ- Equivalence ratio
FCR - rate of consumption of rice husk, kg/hr
SA - stoichiometric air of rice husk, kg air per kg rice husk
ρair - air density, kg/m3
Superficial Air Velocity

26
This refers to the speed of the airflow in the fuel bed. The velocity of air in the bed of
rice husks will cause channel formation, which may greatly affect gasification. The
diameter of the reactor (D) and the airflow rate (AFR) determine the superficial velocity
of air in the gasifier. As shown, this can be computed using the formula,
AFR × 4
Superficial velocity (V) = …...equation [2.23]
D2 × π

Where:
V - Superficial gas velocity, m/s
AFR - Airflow rate, m3/hr
D - Diameter of reactor, m
Resistance to Airflow
This refers to the amount of resistance exerted by the fuel and by the char inside the
reactor during gasification. This is important in determining whether a fan or a blower
is needed for the reactor. The thickness of the fuel column (Tf) and the specific
resistance (Sr) of rice husk, which can be determined with aid of figure below, will give
enough information for the total resistance needed for the fan or the blower. As shown,
this can be computed using the formula[7],
Rf = Tf × Sr … equation [2.24]
Where:
Rf - resistance of fuel, cm of H2O
Tf - thickness of fuel column, m
Sr - specific resistance, cm of water/m of fuel

Figure 2. 13: Superficial velocity vs pressure

drop graph

Source: (Belonio 2005)

27
2.6.6 Cyclone separator design
Designing cyclone separator means determining dimension of cyclone. Ergo, following
methods can used to compute required dimension from following literature, which is
given below:
Method 1 by Karol Vavro and Peter Hodúr [15]
In the first method, the main dimensions are the diameter of the cylindrical part of the
cyclone, Dc. Proposal the diameter of the cylindrical part of the cyclone depends on the
required critical size, X50 of the separated ones particles. This dependency is shown in
below table:
Table 2. 2: Respective diameter for required critical particle size

Source: (MIČEK 2015)

X50 (10-6 mm) 80 50 30 20 15 10 5

Dc (mm) 4000 2000 1500 1000 750 500 200

To design a cyclone with this method, it is also necessary to select the dimensions of
the inlet opening: width (Be) and height (He). The other dimensions are then determined
according to the so-called simplex[15]:

Dc
=2 till 4……………………………………… ….equation [2.25]
Dp

Dk
= .2 till 1.1 ………………………………………equation [2.26]
Dp

Hv
=.5 till 2………………………………………….equation [2.27]
Dc
Hk
=2 till 4……………………………………………equation [2.28]
Dc

Hc=Hv + Hk………………………………………….equation [2.29]

Hp
=1.5 till 3…………………………………………equation [2.30]
Dp

Where:
Dp = diameter of overflow pipe
Dk = diameter of the outlet from the conical part
Hv = height of cylindrical part
Hk = height of conical part
Hc = total height of cyclone
Hp = sink depth of overflow pipe

28
It must be the case that the depth of immersion of the overflow pipe must be greater
than the height of inlet pipe[15]:
Hp>He
Furthermore, the derived dimensions and quantities are calculated, which will be used
in later calculations. These include[15]:
a) Parameter of the axial distance (ho) of the mouth of the overflow pipe from
wall of the separating cone space:
Dc - Dp
ho= Hv - Hp + D × Hk…………………………. equation [2.31]
c- Dk

For the case: Dk>Dp

ho=Hv - Hp + Hk…………………………………… equation [2.32]
b) Cone angle [o]:
Dc - Dk
Kk = 2arctan( )………………………… equation [2.33]
Hk

c) Distance of the center of gravity of the inlet stream of the mixture into the
separation space, Le [m]:
Dc - Be
Le = …………………………. Equation [2.34]
2

d) Inlet pipe content, Ae [m]:

Ae = Be × He ……………………. Equation [2.35]
For circular inlet, we calculate an equivalent square cross-section according to the
formula,
De × √π
Be = He = ……………………equation [2.36]
2

e) Content of overflow pipe, Ap [m2]:

π × Dp2
Ap = ………………………..equation [2.37]
4

f) Mixture velocity at the inlet to the cyclone, ue [ms-1]:

Ve
ue = A …………………………..equation [2.38]
e

g) Velocity of the mixture in the overflow pipe at the outlet of the cyclone, up [ms-
1]:

Ve
up = A ………………………….equation[2.39]
p

Method 2 by Mel Pell, James B. Dunson and Ted M. Knowlton [15]

According to this method, the basic dimensions of a cyclone are given as multiples of
the cylindrical diameter part, Dc to be selected. In addition to containing only the basic

29
dimensions of the cyclone, shows the most common ratios between the diameter of the
cylindrical part and other dimensions;
Dc
Be = ……………………………….equation [2.40]
4
Dc
He = ……………………………....equation [2.41]
2
Dc
Dp = ……………………………….equation [2.42]
2
Dc
Dk = ……………………………….equation [2.43]
4

Hk = Hv = 2 × Dc……………………..equation [2.44]
Dc
Hs = ………………………………..equation [2.45]
8

Hp = He + Hs…………………………..equation [2.46]
Where:
Hs – Overflow pipe overhang below the level of the lower edge of the inlet pipe

Figure 2. 14: Design dimension of cyclone separator

Source: (MIČEK 2015)

2.6.7 Dry filter design

According to literature (D S Mandwe 2006), the experiment carried out for a dry filter
by PAU Ludhiana has concluded that the tar content in the producer gas after filtration
was less than 80 mg/m3.The retention period of gas in the filter bed height of 50 cm
was found to be 10 seconds. The optimum retention period was considered 10 to 12
seconds. The velocity in the filter was estimated to be[16]:

30
 bed height
Velocity (Vd) = retention period ……………………………equation [2.47]

The diameter of the filter with Vd was estimated as:

gas flow rate (Q)
Dd = √ π …………………equation [2.48]
Vd ×
4

2.7 Performance Analysis

After completion of fabrication, next step was testing and evaluating its operating
performance. Ergo, according to literature[7],
Most commonly used method in testing the performance of the rice husk gasifier,
however, is the combination of the water boiling and simmering tests, which allows a
certain volume of water to boil and simmer until all the fuel is consumed in the reactor.
During the test, the operating performance of the stove in terms of start-up time to ignite
rice husk fuel, ignition time to generate gas, total operating time, time to boil a certain
volume of water, amount of fuel used, and amount of char produced after each operation
were determined. Temperature profile of water during boiling is determined in this test
from the time the pot is placed on the burner until all the fuel is completely gasified.
2.7.1 Test parameter
Now, some of test parameters are as follows:
Startup time (ST)
Measured from the time between burning introduced to the fuel in the reactor and time
until combustible gas produced at the burner [7].
Operation time (OT)
Duration from the time the gasifier produces a combustible gas until no more gas is
Obtained from the burning rice husks[7].
Total Operating Time
Duration from the time rice husks are ignited until no more combustible gas is produced
in the stove. It is the sum of the startup time and the operating time[7].
Fuel Consumption Rate (FCR)
This is the amount of rice husk fuel used in operating the stove divided by the operating
time. This is computed using the formula[7],
Weight of Rice Husk used (kg)
FCR = ………………equation [2.49]
OT(hr)

Specific Gasification Rate (SGR)

31
This is the amount of rice husk fuel used per unit time per unit area of the reactor. This
is computed using the formula[7],
Weight of Rice Husk used (kg)
SGR = ……………..equation [2.50]
Reactor Area (m2) × OT(hr)

Sensible Heat (SH)

This is the amount of heat energy required to raise the temperature of water. This is
measured before and after the water reaches the boiling temperature. This is computed
using the formula[7],
SH = Mw x Cp x (Tbw – Ti)…………………….equation [2.51]
Where:
SH - sensible heat, Kcal
Mw – mass of water, kg (1kg/liter)
Cp – specific heat of water, 1 Kcal/kg-°C
Tbw– temperature of water at boiling, approx. 100°C
Ti – temperature of water before boiling, 27-30°C
Latent Heat (LH)
This is the amount of heat energy used in evaporating water. This is computed using
the formula[7],
LH = We x Hfg……………….equation [2.52]
Where:
LH - latent Heat, Kcal
We – weight of water evaporated, kg
Hfg – latent heat of water, 540 Kcal/kg
Thermal Efficiency (TE)
This is the ratio of the energy used in boiling and in evaporating water to the heat energy
available in the fuel. This is computed using the formula[7],
SH + LH
TE = LHV × WF…………………..equation [2.53]

Where:
TE - thermal efficiency, %
SH - sensible heat, Kcal
LH - latent heat, Kcal
LHV - heating value of fuel, Kcal/kg
WF - weight of fuel used, kg

32
2.8 Some Prior Studies for Fixed-bed Gasification System
(Ojolo 2012) had developed laboratory scale updraft gasifier using sawdust and palm
kernel shell as source of fuel and had investigated its performance. Ergo, lower heating
value of sawdust and palm kernel shell were found 22200 Kj/kg and 15000 Kj/kg
respectively via aid of proximate and ultimate analysis simultaneously; and dimension
of reactor as diameter and height. After performance (Ojolo 2012) testing, his design’s
efficiency were 93% and 67.4% with respective to sawdust and palm kernel shell
respectively[3].

(Ramzy E. Konda 2014) had fabricated and evaluated updraft fixed-bed gasifier having
output capacity as 50 Kw, oils palm fronds as fuel source, square type reactor and
modified air supply system. Ergo, conclusions were: the air gasification results of oil
palm fronds showed volumetric percentage of 22.62-23.35% of CO, 6.48-6.68% of H2,
1.2%-1.5% of CH4, 9.51-5.65% of CO2 and 59.2-58.1% of N2, the heating value of
producer gas was found to be 4.1-4.4 MJ Nm-3, cold gas efficiency was 57-59% and
specific gasification rate was 103-106 kgm-2hr-1[2].

(Prince Yadav1 2013) had constructed updraft biomass gasifier to check composition
of producer gas using wood chips, sugarcane waste and coconut shell as raw material
(feed). Ergo, findings were: percentage of wood chips was greater than percentage of
sugarcane wastes was greater than percentage of coconut shell of CO2, percentage of
coconut shell was greater than sugarcane was greater than wood chips of CO2, percent
of CO was similar order to percentage of CH4 and so on[17].

(P. E. Akhator 2019) had investigated theoretical and experimentally about developing
gasifier with cleaning system. Ergo, this literature gives detail of constructing and
testing of small-scale downdraft gasifier having thermal capacity as 5Kw, wood chunks
and wood shaving as fuel source, reactor with hopper and throat, cyclone separator, wet
and dry filter filtration system. Thus, conclusions were: stable blue flame was produced
that can use in internal combustion engine, in cooking purpose and in generating
electricity while fuel consumption rate 1.25 kg/hr for wood chunks and 2.1 kg/hr for
wood shavings[4].

33
(ADEWUYI 2019) had designed and developed laboratory scale updraft gasifier with
wood as fuel source, had performed performance analysis and feed analysis. Ergo,
literature gives its result as follows[18]:

1. The results of the proximate analysis of the wood showed that the respective
moisture content of 45.9% (dry basis) contains 50.9% fixed carbon, 85% of volatile
matter and 20% of ash content,
2. The higher heating value (HHV) and low heating value (LHV) are 8409.65 KJ/kg
and 7807.45 KJ/kg,
3. The result of ultimate analysis gives some elemental compositions, which are
carbon (18.9%), hydrogen (2.74%), nitrogen (0.58%) and oxygen (11.88%), (G
Suresh Kumar 2018)
4. Start-up Time (mins) 75, Operating Time (mins) 10, Weight of Wood Used (kg)
4.3, Fuel Consumption Rate (kg/hr) 25.29, Specific Gasification Rate (kg/m2-hr)
815.9 and Combustion Zone Rate (m/hr) 5.9.

(Nikhil Ashok Ingle 2015) had fabricated and tested 20 Kw downdraft gasifier having
reactor with hopper and throat. The main focus was to find right mixture of feed to run
gasifier. Thus, conclusions of this literature were[19]:

1. Wood pieces of size 30-50 mm are best suitable as a feedstock than of the size
greater than that.
2. Calorific value of gas from wood blocks of 100-150mm size is 3.213 MJ/Nm3.
3. Calorific value of gas from biomass briquettes is 2.447 MJ/Nm3.
4. Calorific value of gas from wood blocks of <50mm size is 3.978 MJ/Nm3.
5. Calorific value of gas from coconut shells mixed with wood is CV= 4.865 MJ/Nm3.
6. Wood has more calorific value than agricultural biomass briquettes as it has more
CO and H2 content.
7. When coconut shells are mixed in wood its calorific value increases.
(Alok DHAUNDIYAL 2016,) deals with performance evaluation of downdraft gasifier
using pine needles as fuel source. Then, tar and dust contents were evaluated using non-
isokinetic sampling techniques. After performance analysis, findings were[20]:
1. The carbon dioxide and carbon monoxide emission at the exhaust of engine was in
the range of 12.8% and 0.1–0.5% respectively.

34
2. The maximum temperature of producer gas measured at the outlet of the gasifier
was 505 °C.
3. The specific biomass consumption rate of pine needles was calculated to be 1.595
kg/hr. Specific gasification rate for the given design was found to be 107 kg/m2hr.

35
 CHAPTER THREE: METHODOLOGY

This section describes concept of this project’s methodology, which are as follows:
3.1 Reviewing of Literature:
As given at chapter two, for initiating this project’s methodology, more than twenty
literatures were reviewed. Thus, after brainstorming, conclusions were: using design
steps for designing gasifier from literature (Belonio 2005)[7] and for filtration, half
cyclone with dry filer were designed from literatures (MIČEK 2015) [15] and (D S
Mandwe 2006)[16] simultaneously.

3.2 Design Parameters

(Belonio 2005) had concluded that design of gasifiers were based on empirical data,
which differ from one another design.

3.2.1 Design considerations

After conducting several test of (Belonio 2005)’s design of rice husk gas stove, he had
reached his conclusion that before designing several factors should be considered,
which affect efficiency of gasifier[7]:

a) Type of Reactor:
The operating performance of the rice husk gas stove depends on the type of the reactor
used. Although there are several types of combustor that can be used for rice husks, the
Top lit updraft or Inverted downdraft under the downdraft type gasifier was proven to
work well with this waste material as compared with the traditional bottom-lit
downdraft type, cross-draft type, or updraft-type reactors.
b) Cross sectional area of Reactor:
Wider the area, more the output is available. Because the area where, feed is burnt and
is gasified to produce syngas
c) Height of the Reactor:
The height of the reactor determines the time taken by the gasifier can be operated
continuously and the amount of gas that can be produced for a fixed column reactor.
The higher the reactor, however, the more pressure draft is needed to overcome the
resistance exerted by the fan or by the blower.
d) Thickness of Fuel Bed:
The thickness of the fuel bed is only considered when designing a cross-draft gasifier.

36
Fan or blower provides the necessary airflow that is needed for the gasification of rice
husks. The fan to be used should be capable enough to overcome the pressure exerted
by the rice husks and, subsequently, by the char. A high-pressure fan is usually ideal
for downdraft type reactor, while low-pressure fan issued for cross draft type reactor.
e) Burner type:
There is a need to retrofit the burner design to allow proper combustion of fuel gas.
Retrofitting includes enlarging of the inlet pipe of the burner and the provisions of a
cone to induce secondary air, thereby making the gas properly ignited and burned.
f) Insulation of Reactor:
The gasifier reactor need to be properly insulated for two reasons: First, this will
provide better conversion of rice husk fuel into gas. Second, this will prevent burning
of skin when they accidentally touch the reactor’s surface.
g) Location of Firing the Fuel:
Rice husk fuel can be fired in the stove in different ways. For fixed bed gasifiers, like
the downdraft reactor, rice husk fuel can be fired starting from the top or from the
bottom (Bottom Lit) of the reactor. So far, for an inverted downdraft type gasifier, firing
the fuel on top is the best and easiest way. Firing the fuel in this manner minimizes
smoke emission.
h) Size and Location of the Char Chamber:
The size of the chamber for carbonized rice husks determines the frequency of
unloading the char or the ash. Bigger chamber can accommodate larger amount of char
and can allow longer time before the char is removed. In addition, designing shorter
chamber will give sufficient height for the stove reactor and the burner.
3.2.2 Design assumptions:
Assumption was given to thermal power output, thermal efficiency, operation time and
diameter of cyclone separator. Some Standard values for design parameter were taken
from different literature. Ergo, these assumptions are listed below in table:
Table 3. 1: Assumptions

Description Value Remarks

Gasifier output(Op) 3-5 KW (2579.4- Assumed

4299kcal/hr)

37
 Operating time(T) 0.5 hr Assumed

Efficiency (ɳ) 40-60 % Assumed

2
Specification Gasification 110- 210 kg/hr m [7]
Rate(SGR)

Lower heating value of 3000kcal/kg [7]

fuel(LHV)

Equivalence ratio(ϵ) 0.3-.4 [7]

Stoichiometric air (SA) 4.7 kg air/kg fuel [7]

3
Air density (ρair) 1.25kg /m Universal

3
Bulk density of fuel(ρ) 100-120 kg /m [7]

Syngas energy content(Hv) 812.1-1146.5 [7]

kcal/m3
Diameter of cyclone( Dc) .2m Assumed

3.2.3 Design parameter for gasifier

Required dimensions were calculated by taking the help of some standard value from
literature as far as possible and by assuming some data require for calculation.

Basic parameter for feed

Lower heating value of fuel (LHV)
It was taken as standard value from (Belonio 2005)[7]as shown assumption table 4:

LHV = 3000 kcal/kg

Heating value of producer gas (Hv)

Energy content of producer gas was taken as standard value from (Belonio 2005)[7],
which is given as:
Hv = 3.2 – 4.8 Mj/m3 = 812.1-1146.5 kcal/m3
Stoichiometric Air (SA) and Equivalence Ratio (ϵ) for rice husk

38
These values were taken as standard data from (Belonio 2005)[7] , which is listed
below:
SA = 4.7 kg of air per kg of fuel
ϵ = .32
Specific Gasification Rate (SGR):
The value of SGR was taken as 120 kg/ hr m2 from (Belonio 2005)[7].

Bulk density of feed (ρ):

The value of ρ was taken as 100 kg/m3 from (Belonio 2005)[7].
Reactor parameter:
Now, reactor parameters that need to be considered in determining the appropriate size
of the rice husk gasifier, taking into consideration the power output desired. The size of
the gasifier can be easily estimated by computing these parameters[7]. Ergo, such
parameters are as follows:
Fuel Consumption Rate (FCR)
It was calculated using equation [2.19].
1 4299
FCR = Op× LHV × ɳ = 3000 ×.6 = 2.4 kg/hr

Diameter of reactor (D)

It was calculated using equation [2.20].
√1.27FCR √1.27×2.4
D= = = .16m
√SGR √120

From equation [2.21],

πD2
Area of reactor = =L2
4

Width of reactor (L)

π × D2 π ×0.162
L =√ =√ =.14m
4 4

Reactor height (h)

It was calculated using equation [2.22].
SGR 120
h = T× = .5× = .6m
ρ 100

Airflow rate (AFR)

It was calculated using equation [2.23].

39
 ϵ × FCR× SA .32 × 2.4 × 4.7
AFR = = = 2.9 m3 /hr
ρair 1.25

However, for this project we had taken AFR as .825 m3/min, which was given by blower
having rating 110 watt.
Superficial velocity (V)
It was calculated using equation [2.24].
AFR × 4 2.9 × 4
V= = = .04 m/s
D2 × π .162 × π × 3600

New superficial velocity (Vnew)

AFR × 4 .825 × 4
Vnew = = = .684 m/s
D2 × π .162 × π × 60

Resistance of fuel (Rf)

It was calculated using equation [2.25].
Rf = Tf x Sr[7] = .6 ×.9 = .54 cm of water

Outlet diameter of gasifier (Dg)

For range of heating capacity of syngas from 812.1 to 1145.5 kcal/m3
When Hv = 812.1 kcal/m3
Volume flow rate of producer gas (Q)
Op 4299
Q = Hv= 812.31= 5.3 m3 /hr

Similarly, when Hv = 1146.5 kcal/m3

4299
Q = 812.31= 3.7 m3 /hr

Then, for Q ranging from 3.7 to 5.3 m3/hr

When Q = 3.7 m3/hr.
1.27 × Q 1.27 × 3.7
Dg = √ =√.684 × 3600 = .044 m
Vnew

When Q = 5.3 m3/hr,

1.27 × Q 1.27 × Q
Dg = √ =√.684 × 3600 =. 𝟎𝟓 𝐦
Vnew

However, outlet of gasifier was taken as 0.1m for fast operation.

Table 3. 2: Summarized design parameters of gasifier

Design parameter Value

FCR 2.4 kg/hr
D .16m

40
 h ,6m
L .14m
AFR 3min/m3
V .04m/s
Vnew 2.5m/s
Dg 0.1m
Rf .54 cm of water
For this design parameters, labelled 2D figure is attached in APPENDIX-I.
3.2.4 Design parameter for half cyclone filter
Necessary dimensions for half cyclone filter were computed by using standard formula
through aid of literature review as far possible and by considering if necessary.
Inlet opening width (Be)
It was calculated using equation [2.40].
Dc 0.2
Be = = = 𝟎.05m
4 4

Inlet opening height (He)

It was calculated using equation [2.41].
Dc 0.2
He = = = 𝟎.1m
2 2

Diameter of overflow pipe (Dp)

It was calculated using equation [2.26].
Dc 0.2
Dp = = = 𝟎.1m
2 2

Height of cylindrical part (Hv)

It was calculated using equation [2.38].
Hv = 1.25 × Dc = 1.25×.2 = 𝟎.25m

Sink depth of overflow pipe (Hp)

It was calculated using equation [2.30].
Hp = 1.75 × Dp =1.75 × .1 =.175m
Table 3. 3: Summarized design parameters of half cyclone filter

Design parameter Value

Be .05m
He .1m
Dp .1m

41
 Hv .25m
Hp .175m
For this project, labelled 2Ds are attached within APPENDIX-III.
3.2.5 Design parameter for dry filter system
Required parameters were calculated by use of standard formula as far as possible. In
addition, if required, some parameters were assumed.
Filter bed height (Hf)
Hf = .1m[16]
Retention time (Tr)
Tr = 2 sec[16]
Velocity of gas through the bed (Vd)
It was calculated by using equation [2.46].
Hf .1
Vd = Tr = = .05m/s
2

Now using equation [2.47],

gas flow rate (Q) 5.3
Diameter of filter, Dd = √ π [16] = √0.05 × 3600 × π = .2m
Vd ×
4 4

For labelled 2D figure, review APPENDIX-IV.

3.3 3D Drawing
First, ideology of small-scale updraft gasifier system was converted into virtual view
or 3D view through Solidworks2014 software, which is shown figure below:

(a) (b)
Figure 3. 1: (a) 3D view of gasifier and (b) 3D of gasifier with
simple filtration system

42
3.4 Material Selection
For conducting the project, following materials were:

1. Raw material: rick husk as feed, paper or cardboard for starting fire
2. Fabricating material: four/two mm sheet metal, nut and bolt, iron rod, iron pipe
a) We had visited scrapyards for searching of iron sheet for balancing financial
assistance. Ergo, leads to obtaining .004 m iron sheet, which had been use for
constructing reactor, and rectangular shape iron having alternative rectangular
shaped having semi-circle at both ends gap pattern, which was obtained from
scrapyard was used for grate.
b) For other parts, 0.002 m iron sheet had used.
c) In addition, 15mm and 10 mm nuts and bolts, iron rod of 10mm as diameter were
used as for requirements.
3. Machinery used: drilling machine, rolling machine, wielding machine
4. Measuring instrument used: sprit level, measuring tape, stopwatch, weight balance,
thermometer,

3.5 Fabrication Procedure

Now, next step is fabrication then, detail construction of this project is explained in
stepwise as below:
Reactor construction and Insulation construction
a) 0.004m iron sheet had been layout into rectangular shape of dimension of 0.6m *
.6m and divided to four small rectangle of dimension of 0.14m*0.14m. After lay
outing, angle grinder had been use to cut marked area.
b) At Grill house, edges of four small rectangle had been weld through one phase
welding machine but not overlapping each other, with technical assistance of to
form cuboid shaped reactor.
c) Square having dimension as .15*.15m were cut from .002m iron sheet and four
holes of diameter .001m is drilled at 90o at distance of 0.06m from center while
another four holes at 45o.
d) Then, two square having dimension as .15 m * .15 m were cut from center making
square as dimension of 0.09m * 0.09m.
e) Out of two square of dimension as .15 m * .15 m, one was weld to reactor while
other holes were weld with nuts of diameter of .001m respectively.

43
f) Different literatures are available about critical thickness of cylinder and sphere but
for cuboid duct, there is no any availability of source about thickness level.
g) For insulation construction,
1. Thin sheet metal having cylinder shaped of dimension
2. Mixture of concrete and rice husk ash in 1:1 proportion was made and was poured
between cylinder shaped thin sheet and reactor.
3. After this process, it had been let to rest for 3-4 days for setting.
h) For 2D drawing with labelled dimensions, review APPENDIX-I.
i) Completed weld figure and 3D drawing for this process is shown below;

[a] [b]
Figure 3. 2: [a] 3D of reactor and [b] Section view of reactor

Figure 3. 3: Fabricated
reactor

44
Char chamber construction
1. 0.002 m iron sheet had been layout into four rectangular shape of dimension of
0.3m*0.15m for front, left, right and back side and two rectangular shape of
dimension of 0.3*0.3m for top and bottom side. After lay outing, marked area had
been cut via angle grinder.
2. For front side, first rectangle of dimension of .3*.15m,
a) From center of any edge, rectangle of dimension .13 * .16m had been cut equally
toward right side and left aside for char outlet.
b) After this step, three holes having diameter as .015m had been drilled at angle of
90o from center of rectangle having dimension as .13m *.16m via hand drill
machine.
c) Welding of three15mm bolts were done to hold cover of char outlet.
d) Cover of char chamber outlet is rectangular having dimension of, holes were drilled
that matches for 15 mm bolt pass through it.
e) At last, handle having U-shaped made by 0.002m iron sheet having height as 0.04m,
while have .08m as shorter side/legs and longer side as .1m and was weld at center
of cover of char chamber outlet.
3. For left side, second rectangle of dimension of 0.3m*0.15m
a) It had been mark at center of edge of any side; from center, rectangular shape of
0.08m*0.08m had cut equally towards right side and left side respectively.
b) Hole having diameter as .015 m was drilled at distance 0.03m from upper edge and
0.06m from left edge through drill machine for insertion of grate rod.
c) .015m nuts were weld on both sides of drilled whole and outer side of it was weld
with 0.002 m sheet having dimensions as .04 *0.04m before welding nut for locking
grate mechanism.
4. For right side, rectangle of dimension of 0.3*0.15m ,
a) Hole having diameter as .015 m was drilled at distance 0.03m from upper edge and
0.06m from left edge through drill machine for insertion of grate rod.
b) .015m nuts were weld on both sides of drilled hole and outer side of it was weld
with 0.002 m sheet having dimensions as .04 *0.04m before welding nut for locking
grate mechanism
5. For top side, rectangle having dimension of 0.3m * 0.3m,
a) It had cut at middle center; from center, 0.7m towards all side had been cut into
rectangular shape of dimension of 0.14m*0.14m for insertion of reactor.
45
6. For bottom side, rectangular shape metal sheet having dimension as 0.3 *0.3, four
legs having cuboid shape dimension as 0.05*0.05*.08m were weld at each corner
and again a piece metal as washer size were weld at each legs.
7. Support frame was constructed as shown in figure below:
8. For 2D drawing with labelled dimensions, review APPENDIX-II.
9. Completed weld figure and 3d figures for this process is shown below:

(a) (b)

Figure 3. 4: (a) 3D of char chamber and (b) Section view of char chamber

Grate Lever Support for Reactor and

Airflow System

Char Outlet

Figure 3. 5: Fabricated char chamber

Grate mechanism construction

1. Pre-manufactured rectangular shaped iron sheet having pattern of alternative
rectangular shaped having semi-circle at both side i.e. breadth side gap had been cut
into rectangular of dimension 0.18m *0.18m.

46
2. In addition, it had been weld with iron rod having .015 m bolt weld on both sides,
but washer (piece of sheet metal having thickness 0.002m ) having dimension as
.03m *.03m and .015m nuts were weld at both side of rectangular piece of
dimension of .15m*0.3m as described in char chamber construction section. At one
side, a piece of iron lever was weld to control the grate.
3. Grate was tight loosen due to nut at one side and lever is used to control the grate.
4. Note: grate gaps should in range from 0.001m-0.006m in diameter.
5. For grate, review APPENDIX-II.
6. 3D Figure and Fabricated grate mechanism for this process is shown below or aside:

Figure 3. 6: 3D of grate with grate rod

(a)
(b)
Figure 3. 7: Fabricated grate mechanism: (a) when open and (b) when close

Cyclone construction
1. First, Layout was done on 2mm iron sheet into rectangle of .6m * .5 m.
2. After layout, rectangle was rolled into .2 m circle by roller machine.
3. It was cut into two half having height .25m. Then, one of side was cut into arc
having radius 0.05m and depth .1m.

47
4. For overflow pipe, pre-manufactured cylindrical pipe having radius .05m with cut
into height of .18m.
5. For top side cover,
a) First, 2mm sheet was cut into square having dimension as .25 *.25m.
b) Then, circle was cut at radius of .1m and at radius of .2m from center.
6. For bottom side cover,
a) First, 2 mm sheet was cut into square having dimension as .25 *.25m.
b) Then, four holes having diameter as 10mm were drilled at 90o from center at
distance of .11m, while another four holes were drilled at 45o from center at distance
of .12m.
c) Again, similar procedures as in b) were introduced to other sheet after constructing
top side.
7. Last, all parts were weld and 10 mm screw at respective holes were weld as shown
in 2D and 3D figure.
8. Square iron rod having width as .01m was weld around the edge of above square
having dimension as .25 * .25 m, which was weld to main body for structural
alignment.
9. For this process, 3D figure is given below:
10. For 2D figure, review APPENDIX-III.

(a) (b
Figure 3. 8: (a) 3D of half cyclone filter and (b) Section view of half cyclone
filter

Dry filter construction

1. First, cylinder available after completing cyclone filter was 10 mm iron having
height .01m was weld at inside surface of cylinder at 90o from center at height of
.1m from any ends.
2. Then, 2mm sheet was cut into square having dimension as .4m *.4m and four holes
having diameter as 15mm were drilled at 90o from center at distance of .3m.

48
3. After drilling, four 15mm screws were weld.
4. Last, whole system were weld at top side of cyclone filter as shown in 3D figure.
5. For this process, 3D figure is shown below:
6. For 2D figure, review APPENDIX-IV.

(a) (b)
Figure 3. 9: (a) Section view and (b) 3D of dry filter

Figure 3. 10: Fabricated gasifier system with insulation

49
3.6 Testing Procedure:
Following step were adopted, which are as follows:
1. Gasifier system was fabricated for ready for operation; was made sure for operation
2. Fresh and dried one kg of rice husks were prepared.
3. Test equipment such as weighing scale, thermometer, and volumetric cylinder were
prepared.
4. Mass of fuel to be loaded in the gasifier was measured before operating.
5. Water to be boiled was prepared, volume and initial temperature of water were
recorded.
6. Paper/ cardboards were prepared for ignition; the start-up time as well as the amount
of ignition fuel used were recorded.
7. Gas coming out of gasifier was ignited at equal interval of time for checking of
ignition.
8. Gas coming out of gasifier if ignited then it was recorded from the starting time of
ignition to the time until no combustion.
9. Pot was filled with prescribed water and was covered with lid.
10. The time was recorded when the pot is placed on the ignition gas to point when
water reached its boiling point. In addition, the temperature of water at one-minute
interval was recorded until the boiling point is reached.
11. Water was boiled continuously until all the fuel in the reactor was totally consumed
and no more combustible gas was produced. Also, the mass of remaining water in
the pot after the test was recorded.
Some figures during performance are shown below:

(a) (b)

Figure 3. 11: (a) Filling of rice husk and (b) Ignition flame after starting time

50
 Figure 3. 12: Testing

(a) (b)

Figure 3. 13: During testing: (a) boiling testing and (b) bubbling of water

51
 CHAPTER FOUR: RESULT AND DISCUSSION

4.1 Result of the Feed Source Analysis:

Proximate Analysis and Ultimate Analysis of Rice Husk were not done because of lack
of equipment availability and due to COVID pandemic. However, standard values from
literature, which had been described in chapter two, were introduced for this project.

4.2 Result of the Test Parameters for Rice Husk

Before conducting test, preheat of gasifier system for better output. After conducting
testing as described in testing procedures, following data were obtained, which is listed
as below:
Table 4. 1: Test results

Trial 1 Trial 2 Average

Total Started (min) 0.75 0.5 .625
operation time Finished (min) 18.5 19.12 18.81
Startup time 6.25 4.58 5.42
Weight of fuel used (WF) [kg] 1 1 1
Volume of Initial (m3) .0005 .0005 .0005
water Final (m3) 3.75 × 10-4 3.65 × 10-4 3.7 × 10-4
Water Initial (oC) 27 27 27
temperature Final (oC) 100 100 100
Boiling time 5.02 4.05 4.54

Then,
πD2 π.162
Area of reactor = = = .02011m2 [D from design calculation section]
4 4

Operation time (OT) = 18.87 - 5.42 - 0.625 = 0.214 hr

Specific heat of water (Cp) = 1 Kcal/kg-°C
Mass of water (Mw) = 1000 × .0005 = 0.5 kg [Density of water = 1000 kg/m3]

Weight of water evaporated (We) = 1000 × 3.7 × 10-4 = 0.37 kg [Density of water =
1000 kg/m3]

Latent heat of water (Hfg) = 540 Kcal/kg

From equation [2.49],

52
 Weight of Rice Husk used (kg) 1
FCR = = = 4.7 kg/hr
OT(hr) .214

Using equation [2.50]

Weight of Rice Husk used (kg) 1
SGR = = = 233.5 kg/m2 hr
Reactor Area (m2) × OT (hr) .02011×.214

From equation [2.51],

SH = Mw × Cp × (Tfw – Ti) = .5 × 1 × (100 - 27) = 36.5 Kcal
From equation [2.52],
LH = We × Hfg = .37 × 540 = 199.8 Kcal
Using equation [2.53],
SH + LH 36.5 + 199.8
TE=LHV × WF = = 7.88 % [ LHV = 3000 Kcal/kg from design calculation
3000 × 1

section]
Again, completed feed capacity of this project’s gasifier system is 1.5 kg. However,
for two trials, 1 kg of rice husk were used; which leads results, which is listed below
in table 4.2:
Table 4. 2: Testing parameter values

Testing parameters Value

Operation time 0.214 hr
Fuel Consumption Rate 4.7 kg/hr
Specific Gasification Rate 233.5 kg/m2 hr
Thermal efficiency 7.88 %
Above calculated test parameter formula were taken from (Belonio 2005). In
(Belonio 2005), using .975 kg of rice husk as testing purpose; then, total operation
time, FCR, SGR and TH was found to be .49 hr, 2 kg/hr, 113.63 kg/m 2 hr, 13.1%
respectively. However, total operation time of this project is three times less than
(Belonio 2005), FCR and SGR is twice more than (Belonio 2005), and thermal
efficiency was 4% less than (Belonio 2005). Thus, possible reasons for these
deviations may be due to outlet larger area, which was fabricated for filtration
system inlet or due to large airflow system, which was also taken based on
filtration system, while others reasons may be chances of heat loss, and high
moisture content.
4.3 Result of Syngas Analysis and Temperature Profile
Composition of syngas and temperatures at different height of reactor were not
accomplished due to lack of equipment and COVID-19

53
 CHAPTER FIVE: CONCLUSIONS AND

RECOMMENDATIONS

5.1 Conclusions
This project is based on utilization of agricultural wastes using technology called as
updraft gasification. Thus, this project dealt with designing of fixed-bed updraft
gasifier, cyclone separator and dry filter and testing of updraft gasifier was
accomplished. Using input parameters such as feed energy content, stoichiometric air,
equivalence ratio, specific gasification rate, bulk density of feed source, which were
taken as standard values from literature while operation time, gasifier efficiency, output
power were taken as assumed values for calculating design parameters of small-scale
updraft gasifier. For design of half cyclone and dry filter, input parameters like retention
time, and syngas heat content were taken from literature, whereas diameter of cyclone
was assumed. Thus, these design parameters of gasifier, cyclone separator, dry filter
and ideology of char chamber were constructed into 3D model through solid works
software. By considering design parameters such as width as .14m and .6m of reactor
and 3D model, fabrication was accomplished.

Testing of designed and fabricated gasifier using rice husk, which was local availability
was done. Gasifier was initially designed with full load capacity as 1.5 kg of feed. At
¾ loading, average of two trial testing result was found to be: total operation time as
18.87 min, 4.7 kg/hr as Fuel Consumption Rate, 233.5 kg/m2 hr as Specific Gasification
Rate and 7.88% as thermal efficiency.

5.2 Recommendations:
After completing this project, we came to know area that it can be made better, which
is given in following points:

1. Proximate Analysis and Ultimate Analysis of Rice Husk should done. Ergo, it can
give exact design parameter because feed source is core part for gasifier.
2. Fabricating of filtration system based on design mentioned on this thesis or other
types for better efficiency of gasifier.
3. Alteration of airflow system might give better result i.e. introducing airflow at three
to four different places in reactor at certain height from each other.
4. For construction or fabrication, use 4mm iron sheet should give as first priority.

54
5. Running of airflow system for ten to fifteen minutes before running might lead to
less moisture content of feed source.
6. Syngas analysis must be done for every trial of testing that helps to know exact
reason of failures of trial.
7. Further, proper construction of boiler and turbine might produce electrical energy
and direct conversion to generator might produce electrical power.

55
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57
APPENDIX-I : 2D of Reactor and Insulation

All the dimensions are in mm.

Figure I. 1: 2D of reactor

I
 All the dimensions are in mm.
Figure I. 3: Top view of reactor with insulation

All the dimensions are in mm.

Figure I. 2: Front view of reactor with insulation

II
APPENDIX-II: 2D of Char Chamber

Figure II. 1: Exploded view of char chamber

All the dimensions are in

mm.
Figure II. 2: Top view of char chamber

III
 All the dimensions are in
mm.
Figure II. 3: Front view of char chamber

IV
APPENDIX-III: 2D of Cyclone Separator

All the dimensions are in

mm.
Figure III. 1: Front view of half cyclone separator

V
mm.
All the dimensions are in

Figure III. 2: Top view of half cyclone separator

VI
 APPENDIX-IV: 2D of Dry Filter

All the dimensions are in

mm.
Figure IV. 1: 2D of dry filter

VII