Plant Design and Economics Project

MEKELLE UNIVERSITY
EIT-M
DEPARTMENT OF CHEMICAL ENGINEERING

STREAM: BIOCHEMICAL ENGINEERING
COURSE TITLE: PLANT DESIGN AND ECONOMICS
PROJECT TITLE: PRODUCTION OF SYNGAS FROM RICE HUSK
PREPARED BY:
NAME ID NUMBER
1) Teklemariam Negash Eitm/ur83233/07

2) Marta Tesfaye Eitm/ur82728/07
3) Abraham Legesse EIT-M/UR/161456/2006
4) Haftom Mezgobo Eitm/82426/07
5) Firaol Kasaye EIT/UR1511/05
6) Yordanos Alem EIT-M/UR/263248/2006
7) Shewit Awetehey EIT-M/UR/262941/2006
Submission Date:
Submitted to: Inst. Gebrehiwot G. (MSc)
Mekelle, Ethiopia
PRODUCTION OF SYNGAS FROM RICEHUSK
CHEMICAL ENGINEERING (BIOCHEMICAL ENGINEERING STREAM) Page i

1 INTRODUCTION
1.1 Background
The traditional fossil fuels (oil, coal and natural gas) continue to be the major sources of energy
in the world. The increasing energy demands will speed up the exhaustion of the finite fossil
fuel. With the current proved reserves and flows, years of production left in the ground coal: 145
years, oil: 41 years, natural gas: 58 years.
Depending of fossil fuels has led to serious energy crisis and environmental problems, i.e. fossil
fuel exhaustion and pollutant emission. Carbon dioxide is the main greenhouse gas, and a major
part of CO2 emissions is due to combustion of fossil fuels. Also combustion of fossil fuel
produces toxic gases, such as SO2, NOx and other pollutants, causing global warming and acid
rain. Several researches have been made to explore clean, renewable alternatives. As synthesis
gas is clean and renewable source of energy it can replace the conventional fossil fuels.
Apart from its use as a source of energy, synthesis gas can be used for various other purposes in
different industries. It is used in hydrogenation process, saturate compounds and crack
hydrocarbons. It is also used in manufacturing of different chemicals like ammonia, methanol
etc.
Gasification is a process that converts organic or fossil based carbonaceous material into a
combustible gas by reacting the material at high temperature with a controlled amount of
air/oxygen often in combination with steam. Biomass as a product of photosynthesis is one of the
most abundant renewable resource that can be used for sustainable production of hydrogen.
Fluidized bed gasifiers are advantageous for gasification of biomass because of their flexibility
in feedstock size and better contact between gases and solid.
In Thailand, the government has encouraged using of biomass as alternative energy and has
financially supported the use of agricultural residue for heat and power production. They
conducted some projects for performance test the feedstock consumption rate, producer gas
yield, heating value of producer gas, and thermal efficiency. Wood, corncob, palm, etc. have
been used as residue for the feedstock. Some projects used producer gas for electrical power
CHEMICAL ENGINEERING (BIOCHEMICAL ENGINEERING STREAM) Page 1

generation with the capacity ranged from 250 to 300 kW and the others produce heat for use in
the ceramics industry, fertilizer drying and hotels, etc.
Viet Nam is an agricultural country with around 60% of population which are working on this
field and the rice production is more than 40 million tons annually. Therefore, every year there
has more than 10 million tones of husk paddy might be used as biomass under different energy
forms. Moreover, it can be seen that, in most studies, heat, bio-oil and synthesis gas are
successfully produced by combustion, pyrolysis and gasification techniques from biomass.
However, the gasification process should be focused and deeply researched which aim to enable
higher process efficiencies, better gas quality and purity, and lower investment costs.
Rice husk belongs to renewable clean energy source. Environment protection and clean biomass
energy is sole renewable energy that can be converted to clean fuel materials. Hazardous
Substances from straw(S&Ash) content is 90% less than bituminous coal.
1.2 Statement of the Problem
Adequate and affordable energy availability is essentially needed for all living beings in all
walks of life. The major energy sources like coal, natural gas and petroleum products are non-
renewable fossil fuels. These are finite and thus can be used only for a finite period. Also,
emissions from non-renewable energy sources are major environmental pollutants. Biomass
energy is the only renewable source that can replace fossil fuels in all energy markets in the
production of heat, electricity and fuels for transport. Depending on this biomass energy fills the
energy gap. There is a potential of producing rice since, about 75% of the weather in Ethiopia is
suitable for growth of rice. Currently there are many farm areas that the crop is mostly available.
As a result, we can generate energy from the rice husk to fulfill the energy demand of our
country.

1.3 Objectives
1.3.1 General Objective
The general objective of the study is production of syngas from rice husk using rice husk
fluidized bed gasification.
1.3.2 Specific Objective
The specific objectives of the study are:

 To know the operational principle of gasification process.
 To characterize and study the chemistry of syngas.
 Designing the major operations that involved during the production of syngas.
 Performing material and energy audit.
 Performing economic analysis of the plant.
1.4 Scope of the Study
The project mainly focuses more about the production of syngas from locally available biomass
which is rice husk. The operation principle and types of gasification, property and composition
of rice husk, process description of the whole gasification process, material and energy audit of
the process, plant site selection, plant layout, equipment sizing and economic feasibility analysis
are well covered through this study.

2 LITERATURE REVIEW
2.1 History of Gasification
Commercial production of syngas from coal, biomass, petroleum coke and various other feed
stocks is capable of generating power in order to produce hydrogen and other liquid fuels or
chemicals, including liquid and gaseous transport fuels. Historically, the relatively low-price and
high abundance of coal made it an ideal choice for production of electric power, but for
environmental and economic reasons there is now a growing interest in the development of
technologies to exploit renewable energy sources such as biomass. Production of high quality
syngas requires a high concentration of H2 + CO and high ratio of H2 to CO and low tar content
for the sufficient use within various energy systems.
Table 1 history of syngas
To produce ‘‘town gas’’ for light and heat.

1850-1940 Gasification of coal- All gas for fuel and light.
To produce synthetic fuel.
1940-1975 To produce liquid fuel & chemicals.
1975-1990 For electric power plant.
2000-present Turnkey thermal power from biomass.
2.2 Gasification process
Gasification is basically a technological process that involves the conversion of carbonaceous

(carbon based) raw material into synthesis gas using heat, steam & pressure. This process
involves the reaction of carbonaceous feedstock with an oxygen containing reagent which may
either be oxygen, air, steam or carbon dioxide, generally at temperatures in excess of 800°C.
This process takes into account the partial oxidation of substance which means that amount of
oxygen is supplied in a limited way such that the fuel is not completely oxidized and it causes
combustion to not occur completely. Although the process is largely exothermic, however, some
heat is still required to initiate the gasification process & to sustain it for effective operation.

Typically, the gas generated from gasification will have a net calorific value of 4–10
MJ/Nm3.The other main product produced by gasification is a solid residue of non-combustible
materials (ash) which contains a relatively low level of carbon.
Chemistry of Gasification: During the process of gasification of solid carbon whether in the
form of coal, coke, char or biomass, the principal chemical reactions are those that involve
formation of the following;
 Carbon
 Carbon dioxide
 Carbon monoxide
 Hydrogen
 Water (Steam)
 Methane.
The reactions that carried out during the gasification process are given as follows;
1. Combustion Reactions:
C + 0.5O2 CO -111 MJ/kmol (1)

CO + 0.5O2 CO2 -283 MJ/kmol (2)
H2 + O2 H2O -242 MJ/kmol (3)
2. Water gas Reaction:
C + H2O CO+H2 +131 MJ/kmol (4)

3. Methanation Reaction:
C + 2H2 CH4 -75 MJ/kmol (5) (5)
Stages of Gasification:
The process of gasification takes place through four different stages which are as follows:
A. Dehydration or drying: The feedstock is dried before the gasification process and the
moisture extracted is used in later chemical reactions.
B. Pyrolysis: Organic materials are thermo chemically decomposed at elevated temperatures
in the absence of oxygen which causes release of volatiles and produces char.
C. Combustion: Is a complete thermal destruction of the fuel (biomass) into CO2 and vapor.

D. Gasification: The char reacts with the carbon dioxide and the steam produced in previous
steps to form carbon monoxide and hydrogen.
Figure 1 steps gasification process

Types of Gasification: There are two types of gasification on the basis of temperature.
1. Low Temperature Gasification: If gasification takes place at a relatively low temperature, such
as 700-1000°C, the producer gas produced will contain a relatively higher percentage of
hydrocarbons as compared to high temperature gasification. As a result, it may be used directly
to be burned for heat or electricity generation via a steam turbine or with suitable gas clean up to
run an internal combustion engine to produce electricity.
2. High Temperature Gasification: This type of gasification involves a temperature range of

1200-1600oC which leads to few hydrocarbons in the product gas, & higher proportion of CO
and H2. The gas produced during this process is called Synthesis Gas, as it is used to synthesize
longer chain hydrocarbons using techniques such as Fischer-Tropsch (FT) synthesis.
2.3 Gasifier
Gasifier is a chemical reactor that converts feedstock (wood, biomass, coal) into a combustible
gas that can be used for heating, cooking and turning turbines for generation of electricity. This
is achieved by partial combustion of feedstock in the reactor and using the heat generated to
pyrolysis or thermally breaks down the rest of the material into volatile gases.

Feedstock + Limited Oxygen = CO2 + H2O + C + Associated Volatile Hydrocarbons + Heat
Thus, the gasifier converts most of the feedstock into the flammable gases with only some ash &
unburned charcoal residue.
Types of Gasifier: Since there is an interaction of air or oxygen and feedstock in the gasifier,
they are classified according to the way in which oxygen or air is introduced in it. So there are
three types of gasifier.
A. Counter current gasifier
The oldest and simplest type of gasifier is the counter current. The air intake is at the bottom and
the gas leaves at the top. Near the grate at the bottom the combustion reactions occur, which are
followed by reduction reactions somewhat higher up in the gasifier. The tars and volatiles
produced during this process will be carried in the gas stream. Ashes are removed from the
bottom of the gasifier.
The major advantages of this type of gasifier are its simplicity, high charcoal burn-out and
internal heat exchange leading to low gas exit temperatures and high equipment efficiency, as
well as the possibility of operation with many types of feedstock (sawdust, cereal hulls, etc.).
Major drawbacks result from the possibility of "channelling" in the equipment, which can lead to
oxygen break-through and dangerous, explosive situations and the necessity to install automatic
moving grates, as well as from the problems associated with disposal of the tar-containing
condensates that result from the gas cleaning operations. The latter is of minor importance if the
gas is used for direct heat applications, in which case the tars are simply burnt.
B. Co-current Gasifier
A solution to the problem of tar entrainment in the gas stream has been found by designing co-
current or downdraught gasifier, in which primary gasification air is introduced at or above the
oxidation zone in the gasifier. The producer gas is removed at the bottom of the apparatus, so
that fuel and gas move in the same direction.
A major drawback of downdraught equipment lies in its inability to operate on a number of

unprocessed fuels. In particular, fluffy, low density materials give rise to flow problems and
excessive pressure drop, and the solid fuel must be pelletized or briquetted before use.

Downdraught gasifier also suffers from the problems associated with high ash content fuels
(slagging) to a larger extent than up draught gasifier.
C. Fluidized Bed Gasifier
Air is blown through a bed of solid particles at a sufficient velocity to keep these in a state of
suspension. The bed is originally externally heated and the feedstock is introduced as soon as a
sufficiently high temperature is reached. The fuel particles are introduced at the bottom of the
reactor, very quickly mixed with the bed material and almost instantaneously heated up to the
bed temperature. As a result of this treatment the fuel is pyrolysed very fast, resulting in a
component mix with a relatively large amount of gaseous materials. Further gasification and tar-
conversion reactions occur in the gas phase. Most systems are equipped with an internal cyclone
in order to minimize char blow-out as much as possible. Ash particles are also carried over the
top of the reactor and have to be removed from the gas stream if the gas is used in engine
applications.
The major advantages of fluidized bed gasifiers, as reported by Van der Aarsen and others, stem
from their feedstock flexibility resulting from easy control of temperature, which can be kept
below the melting or fusion point of the ash (rice husks), and their ability to deal with fluffy and
fine grained materials (sawdust etc.) without the need of pre-processing.
Particularly because of the control equipment needed to cater for the latter difficulty, very small
fluidized bed gasifiers are not foreseen and the application range must be tentatively set at above
500 kW (shaft power).

Figure 2 fluidized Bed Gasifier
Benefits of Gasification
The gasification has the following benefits;

 Gasification converts abundant low-value feed stocks into high-value products.
 Syngas can be used to produce electricity.
 CO2 can be cost-effectively captured from the gasification process.
 Syngas is cleaned before combustion which reduces air pollutants to the atmosphere.
 Limits the formation of large quantities of SOx and NOx.
Disadvantages of Gasification
The process of gasification, although involves a lot of advantage, but it has certain
disadvantages.
 Recovery and use of the bottom ash can be problematic.

 Alkalis can increase agglomeration in fluidized beds that are used in some gasification
systems and also can ruin gas turbines during combustion.

 Tars, heavy metals, halogens and alkaline compounds are released within the product gas
and can cause environmental and operational problems.
2.4 Biomass
Biomass is a natural product of solar energy and therefore, a renewable source of carbon and
hydrogen which are the basic constituents of energy and chemical products. The term biomass
refers to all plant life-trees, agriculture plants, bush, grass and algae and their residue after
processing. Biomass may be obtained from forest, woods & agricultural lands. The term is also
generally understood to include animal & human waste.
Biomass is the organic matter derived from plants as a result of photosynthesis. Photosynthesis is
the process by which solar energy is converted into chemical energy by the plants with help of
pigments called chlorophyll.
6CO2 + 6H2O + Sunlight + Chlorophyll C6H12O6 + 6O2 + Chlorophyll
Rice Production
Rice (Oryza sativa) is grown on every continent except Antarctica and the extent of rice
cultivation covers about one percent of the earth’s surface. More than half of the world’s
population depends on rice as a staple food and it ranks second to wheat in terms of cultivation
area and production. The global production of rice is close to 650 million tons per annum
[www.maps of world.com]. Production of rice is dominated by Asia, where rice is the only food
crop that can be grown during the rainy season in the waterlogged tropical areas.
Properties of Rice Husk
Rice husk is a potential material, which is amenable for value addition. The usage of rice husk
either in its raw form or in ash form is many. Most of the husk from the milling is either burnt or
dumped as waste in open fields and a small amount is used as fuel for boilers, electricity
generation, bulking agents for composting of animal manure, etc [Bronzeoak, 2003; Asavapisit
and Ruengrit, 2005].
The benefits of using rice husk technology are numerous. Primarily, it provides electricity and
serves as a way to dispose of agricultural waste. Rice husk ash, the byproduct of rice husk power

plants, can be used in the cement and steel industries further decreasing the need to import these
materials.
Figure 3 Rice husk
The chemical composition of rice husk is similar to that of many common organic fibers and it
contains of cellulose 40-50 percent, lignin 25-30 percent, ash 15-20 percent and moisture 8- 15
percent [Hwang and Chandra, 1997].
Table 2 Typical rice husk analysis [Bronzeoak, 2003]
S.N Property Range

1 Bulk density (kg/m3) 96 - 160
2 Length of husk (mm) 2.0 – 5.0
3 Ash (%) 22.0 - 29.0
4 Carbon (%) ≈ 35.0
5 Hydrogen (%) 4.0 - 5.0
6 Oxygen (%) 31.0 – 37.0
7 Nitrogen (%) 0.23 - 0.32
8 Sulphur (%) 0.04 - 0.08
9 Moisture (%) 8.0 - 9.0

Advantages of Biomass
 Renewable source of energy.

 When biomass is burnt, the oxygen from the atmosphere combines with the carbon in the
plant to produce CO2 and water. This CO2 and water are again available for the plant
growth and hence cyclic process continues making biomass, a renewable source of
energy (CO2 neutral).
 It is available in majority of geographical locations.
 It is a renewable source of energy in the form of carbon which can be processed into
solid, liquid & gaseous fuel.
 Reduce the usage of conventional fuels and environmental pollution.
 Electrical energy can be produced in large scale at low cost.
Applications of Biomass:
The applications of biomass are as follows:
 Direct thermal application(such as Boiler),

 Bio fuel production such as ethanol for transport applications.
 Generation of electricity.

3 METHODOLOGY
3.1 Raw materials
The raw materials used in the manufacturing of syngas from rice husk are:
 Biomass (Rice Husk)

 Steam
 Air
 Process Water
 Selexol.
3.1.1 Biomass Selection
We have selected the average composition of biomass (rice husk) found in different regions of
Ethiopia. The composition of biomass selected for design purposes is as follows:
Table 3 composition of rice husk
Rice husk %
C 36.66
H2 4.37
O2 31.68
N2 0.23
S 0.04
H2O 8.76
Ash 18.26
3.2 Process Equipment’s
The major equipment’s involved in the production of syngas from rice husk are the following;
1. Rotary dryer
2. Fluidized bed gasifier
3. Heat exchanger
4. Cyclone separator

5. Scrubber
6. Knock out drum
7. Absorber
8. Stripper
9. Cooler
10. Compressor
11. Boiler
12. Turbine
3.3 Processes involved
The major steps of processes involved in the production of syngas from rice husk are:
1. Rice husk preparation
2. Rice husk drying
3. Gasification
4. Gas cooling
5. Gas purification
6. CO2 removal
7. Compression of Syngas
3.3.1 Rice Husk Preparation
Before rice husk is introduced to the rotary dryer it passes through some preparation steps. To
remove dust particles and other unnecessary material associated with risk husk for this purpose
screening is done by using specific sieves keeping in mind the average particle size of rice husk
is 1mm. In case of rice husk as particle size is already quite small therefore further size reduction
is not required.

3.3.2 Rice husk Drying
Next step after preparation of biomass is drying of rice husk as it contains 8.76% moisture so it is
necessary to reduce the moisture contents otherwise it may cause problems in the gasifier
specially in combustion process and will make it difficult to maintain the stoichiometric ratio of
biomass to steam in gasifier and will also increase the load on heat exchanger used after gasifier.
For this purpose rotary dryer is used to reduce the moisture content from 8.76% to 1.42% and the
operating efficiency of the rotary dryer is considered as 85%.

3.3.3 Fluidized Bed Gasification
The rice husk is ready to be introduced in the gasifier. Based on the well mixing of the rice husk
with oxidant the type of gasifier used for this purpose is fluidized bed gasifier. In our case it
makes easier to control biomass and oxidant amounts to be introduced and as rice husk contains
large amount of slag contents so it helps to avoid the slagging of ash in the gasifier.
Air is used as oxidant required for combustion process taking place in the gasifier. Before
introducing it to the gasifier, it is firstly compressed in the air compressor which compresses it to
increase its pressure. The operating power of air compressor is 19kW. After compression it is
then introduced into the gasifier.
Steam is required for the endothermic reactions taking place in the gasifier (partial combustion
and gasification process). It is introduced at a temperature of 400oC and at a pressure of 65 bars
by using a boiler.
3.3.4 Gas Cooling
Syngas leaving the gasifier is at 800oC so it is necessary to remove excess heat from it. This is
done by using a heat exchanger right after the gasifier that reduces its temperature to 500oC and
preheats the boiler water as well. For this purpose shell and tube type heat exchanger is used.
3.3.5 Gas Purification
The Syngas contains large amount of ash contents, water vapors and some quantity of unburnt
rice husk so it is necessary to remove such components from syngas before it can be used as
combustible gas. Solid particles are removed by using a cyclone separator and a filter moisture
contents are removed by using a knock out drum.
3.3.6 Carbon dioxide and Hydrogen Sulfide Removal
The CO2 produced during the gasification process is to be removed by using Selexol solvent. The
CO2 may be used for other industrial applications. The Selexol process uses a physical solvent to
remove acid gas from the streams of syngas. It is ideally suited for the selective removal of H2S
and other sulphur compounds, or for the bulk removal of CO2.

4 MATERIAL AND ENERGY BALANCE
4.1 Material Balance
The material balance is performed in the whole production process starting from the rice husk
feed up to the final product.
Assumptions/Design Specifications:
 Rice husk feed is 1800kg/hr.

 All units we use in the calculation are in kilogram per hour.
 There is no loss.
 The efficiency of dryer to be 85%.
 Syngas leaving the gasifier is at 800oC.
 Steam introduced at a temperature of 400oC and at a pressure of 65 bars.
 The operating power of air compressor is 19kW.
 Efficiency of Cyclone separator is 82%.
 Efficiency of absorber is 99%.
 Selexol enters the absorber at the rate of 500kmol/h.
 The temperature of the rice husk leaving the dryer must not exceed 600C.
 The air enters the dryer at 343K and leaves the dryer at 303k.
 The air enters the gasifier at 400k.
 Temperature of Steam is 673K.
Table 4 Assumed Standards Basis for Calculation
Calorific value of Feed rice husk 12560KJ/kg
Calorific value of rice husk at 1.42% moisture 32660 KJ/kg
Specific heat of water 4.18kJ/kg
Specific heat capacity of rice husk 1.926 kJ/kg.K
Reference temperature 250C
Temperature of rice husk entering gasifier 323K
Temperature of water in to heat exchanger 250C
Temperature of water out the heat exchanger 980C

4.1.1 Material balance on Drier
The rice husk containing moisture is introduced in to rotary drier in order to remove the
moisture. The amount of water removed and the rice husk after drying are computed by
performing material balance on the drier.
𝐤𝐠
F1 = 1800𝐡𝐫 Rotary Drier F2 =?
F3 =?
The amount of outlet stream containing more water is given as follows,

F3 = F1 * 0.0876 * efficiency of dryer.
kg
F3 = 1800hr * 0.0876 * 0.85
kg
F3 = 134hr.
Overall material balance: In order to get the amount of outlet stream containing more dried rice
husk we apply overall material balance.
F1 = F2 + F3
kg kg
F2 = 1800hr - 134 hr
kg
F2 = 1666hr.
Component material balance: The amount of water and rice husk in each stream is given as
follows.
Rice husk component balance: let Xr = composition of rice husk
F1 * Xr1 = F2 * Xr2 + F3 * Xr3, No solid is present in the third stream so, Xr3 = 0.
kg kg
1800hr * (1- 0.0876) = 1666hr * Xr2
Xr2 = 0.986 = 98.6%.

Water component balance: let Xw = composition of water.

F1 * Xw1 = F2 *Xw2 + F3 * Xw3

kg kg kg
1800hr * 0.0876 = 1666hr * Xw2 +134 hr *1
Xw2 = 0.0142 = 1.42%.

For the sake of smooth calculation procedure all the data we gained are given in the table below.
Table 5 Amounts of the Feed Components after Drying
F1 = 1800kg/hr. F2 = 1666kg/hr. F3 = 134kg/hr.

Rice husk (kg/hr.) 1642.32 1642.34 0
Water (kg/hr.) 157.68 23.65 134
C (%) 36.66 39.6 -
H2 (%) 4.37 4.72 -
O2 (%) 31.68 34.2 -
N2 (%) 0.23 0.25 -
S (%) 0.04 0.043 -
Ash (%) 18.26 19.72 -
4.1.2 Material Balance on Gasifier
Air (Fa) =?
Syngas (Fy) =?
F2 = 1666kg/hr.
Fluidized Bed Gasifier
Ash (Fh) =?
Steam (Fs) =?
In order to know the unknown stream first we make component balance on the rice husk
compositions. Using table five we compute the component balance as follows.

Carbon component balance: we know that the syngas contains (CO, CO2, H2S, H2 and N2).
F2 * 0.396 = (Fy * XC0) + (Fy * XC02)
kg
1666 hr*0.396 = Fy (XC0 + XC02)
𝐤𝐠
659.74𝐡𝐫 = Fy (XC0 + XC02) ………………………………………………………………..…… (6)
Hydrogen component balance:

(F2 * 0.0472) + (F2 *0.0142) + 1 * Fs = (Fy *XH2) + (Fy * X H2S)
kg
1666 hr (0.0472 + 0.0142) + Fs = Fy (XH2 + XH2S)
𝐤𝐠
102.3𝐡𝐫 + Fs = Fy (XH2 + XH2S)………………………………………………………………... (7)
Oxygen component balance:

(F2 * 0.342) + (0.5 * F2 * 0.0142) + (0.5 *FS) + (0.21 * Fa) = (Fy * XCO2) + (Fy * 0.5 * Xco)
kg
1666 hr (0.35) + (0.5 *FS) + (0.21 * Fa) = Fy (XCO2 + 0.5 * Xco)
𝐤𝐠
583.1𝐡𝐫 + (0.5 *FS) + (0.21 * Fa) = Fy (XCO2 + 0.5 * Xco)……………………………………… (8)
Nitrogen component balance:

(F2 * 0.0025) + (0.79 * Fa) = (XN2 * Fy)
kg
1666 hr * 0.0025 + (0.79 * Fa) = (XN2 * Fy)
𝐤𝐠
4.2𝐡𝐫 + (0.79 * Fa) = (XN2 * Fy) ………………………………………………………………. (9)
Sulphur component balance:

(F2 * 0.00043) = (Fy * XH2S)
kg
1666 hr *0.00043 = (Fy * XH2S)
𝐤𝐠
0.72𝐡𝐫 = (Fy * XH2S)…………………………………………………………………......…….. (10)
Ash component balance:

(F2 * 0.1972) = Fh
kg
Fh = 1666 hr * 0.1972
kg
Fh = 328.5hr.
Chemical reaction occurred: The chemical reaction which syngas is produced is given as,
2C + H2O + 0.5O2 2CO + H2
Amount of air required: First we calculate oxygen required.

For two carbon half oxygen is required, so the amount of oxygen required for the feed is given
by; first changing the mass basis in to molar basis.
kg
659.74 kmol
hr
Moles of C feed = ( kg ) = 54.98 .
12 hr
kmol
kmol
54.98 ∗0.5 kmol
hr
Oxygen required = ( ) =13.7
2 hr
Amount of air required = moles of oxygen + moles of nitrogen

kmol kmol kmol
Fa = 13.7 +1 = 14.7 .
hr hr hr
kmol kg
Fa = 14.7 * 29kmol
hr
kg
Fa = 426.3hr.
Amount of steam required: The amount of steam required to burn the husk is given as follows,
From the balanced reaction two moles of carbon requires one mole of steam.
kmol
54.98 kmol
hr
Fs = = 27.49 .
2 hr
kmol kg
Fs = 27.49 * 18kmol
hr
kg
Fs = 494.82 .
hr
Overall material balance: The amount of syngas produced from 1800kg/hr feed of rice husk is
given by performing overall material balance on the gasifier.
Mass in = Mass out
F2 + Fs + Fa = Fy + Fh
Fy = F2 + Fs + Fa - Fh
kg kg kg kg
Fy = (1666 hr + 494.82hr +426.3hr ) – (328.5hr)
kg
Fy =2258.62hr. This amount of syngas is produced.
Component balance calculation:

1. Composition of S: The composition of sulpher is known from equation ten.
kg
0.72hr = (Fy * XH2S)
kg
0.72
hr
XH2S = kg = 0.00032.
2258.62
hr
2. Composition of N2: using equation nine we get the composition of nitrogen in the product.

kg
4.2hr + (0.79 * Fa) = (XN2 * Fy)
kg kg kg
4.2hr + (0.79 *426.3hr) = (XN2 *2258.62hr)
kg kg
341 hr = (XN2 *2258.62hr)
XN2 =0.15.
3. Composition of H2: From equation seven.
kg
102.3hr + Fs = Fy (XH2 + XH2S)
kg kg
102.3hr + 494.82hr = Fy (XH2 +0.00032)
kg kg kg
597.12hr = 2258.62 hr * XH2 + 0.72 hr
kg
596.4
hr
XH2 = kg = 0.26.
2258.62
hr
We know that total composition one.

XC0 + XC02 + XH2 + XN2 + XH2S = 1, substituting the known compositions,
XC0 + XC02 + 0.26+ 0.15 + 0.00032 = 1
XC0 + XC02 = 0.589.
XC02 = 0.589 - XC0………………………..…………………………………………………. (11)
Substituting into equation eight,
kg
583.1hr + (0.5 *FS) + (0.21 * Fa) = Fy (XCO2 + 0.5 * Xco)
kg kg kg kg
583.1hr + (0.5 *494.82hr) + (0.21 *426.3hr ) = 2258.62 hr((0.589 - XC0) + 0.5 * XCO)
kg kg kg
920hr = 1330.33 hr 1129.31 hr * XCO
kg kg
-410.33hr = -1129.31 hr * XCO
XCO = 0.36.
From equation eleven we get the composition of carbon dioxide.
XC02 = 0.589 - XC0
XC02 = 0.589 - 0.36
XC02 = 0.23.
Since the syngas contains 15%ash, the total gas produced becomes,
kg kg
Fy = 2258.62 hr + (0.15 * 328.5hr)

kg
Fy = 2308hr. Total gas produced by the gasifier.
Table 6 Compositions of the Gas in each Stream Flow Rate in Gasifier

kg kg kg kg kg
F2 = 1666hr Fa = 426.3hr Fs = 494.82 hr Fh = 328.5hr Fy = 2308 hr
C (%) 39.6 - - - -
H2 (%) 4.72 - - - 25.4
N2 (%) 0.25 79 - - 14.7
O2 (%) 34.2 21 - - -
S (%) 0.043 - - - -
Ash (%) 19.72 - - 100 2.1
H2O (%) 1.42 - 100 - -
CO (%) - - - - 35.2
CO2 (%) - - - - 22.5
H2S (%) - - - - 0.031
4.1.3 Material Balance on the Cyclone
Since the syngas contains ash, so in order to separate the ash the gas is introduced in to the
cyclone separator.
𝐤𝐠
Syngas (Fy) = 2308𝐡𝐫 syngas out (Fy1) =?
Cyclone
Particulate solid (Fp) =?

The efficiency of cyclone is 82%,
Amount of solid in the inlet syngas = 0.021 * Fy
kg kg
Solid in = 0.021 *2308hr = 48.468hr.
Particulate solid = efficiency * solids in

kg
Fp = 0.82 * 48.468hr

kg
Fp = 39.74hr.
Overall material balance: By performing overall material balance we get the syngas out from
the cyclone.
Fy = Fy1 + Fp
kg kg
Fy1 = 2308hr - 39.74hr
kg
Fy1 = 2268.3hr.
Table 7 compositions of the gas in each stream flow rate in cyclone

kg kg kg
Fy = 2308 hr Fp = 39.74hr Fy1 = 2268.3hr
H2 (%) 25.4 - 25.84

N2 (%) 14.7 - 14.96
Ash (%) 2.1 100 0.385
CO (%) 35.2 - 35.82
CO2 (%) 22.5 - 22.89
H2S (%) 0.031 - 0.0315
4.1.4 Material balance on scrubber
The remaining ash is removed using scrubber.
𝐤𝐠
Fy1 = 2268.3𝐡𝐫 Fy2 =?
Scrubber
FP1 =?
kg kg
Amount of solid in = 0.00385 * 2268.3hr = 8.7hr.
kg
Solids removed = FP1 = 8.7hr.
kg kg
Pure syngas = Fy2 = 2268.3hr - 8.7hr

kg
Fy2 = 2259.6hr.
Table 8 compositions of the gas in each stream flow rate in scrubber

kg kg kg
Fy1 = 2268.3hr FP1 = 8.7hr Fy2 = 2259.6 hr
H2 (%) 25.84 - 25.94

N2 (%) 14.96 - 15
Ash (%) 0.385 100 0
CO (%) 35.82 - 35.96
CO2 (%) 22.89 - 22.98
H2S (%) 0.0315 - 0.032
4.1.5 Material Balance on Absorber

The absorption of CO2 is done by Selexol solvent. Selexol solvents are true physical solvents and
do not react chemically with the absorbed gases. The Solvent enters the absorber at the rate of
500kmol/h with no CO2 and H2S.
𝐤𝐦𝐨𝐥
FX = 500 Fy3 =?
𝐡𝐫
A
b
s
o
r
b
e
r
𝐤𝐦𝐨𝐥
Fy2 = 199.4 FX1 =?
𝐡𝐫
Efficiency of absorber is 99%.

kmol
CO2 inlet = 11.8 hr
kmol
CO2 outlet = 0.99 * 11.8 hr
kmol
CO2 outlet = 11.7 hr
.

kmol
H2S inlet = 0.02 hr
kmol
H2S outlet = 0.99 * 0.02 hr
kmol
H2S outlet = 0.0199 .
hr
FX1 = H2S outlet + CO2 outlet + FX

kmol kmol kmol
FX1 = 0.0199 + 11.7 + 500
hr hr hr
kmol
FX1 = 511.72 . This is outlet solvent containing the removed gases.
hr
Amount of syngas: Fy3 = Fy2 - H2S outlet - CO2 outlet

kmol kmol kmol
Fy3 = 199.4 - 0.0199 - 11.7
hr hr hr
kmol
Fy3 = 187.68 .
hr
Since small amount of H2S and CO2 are present with the syngas, so we can neglect.
kg
Fy3 = 1740hr. This is the amount of syngas after absorbition.
Table 9 compositions of the gas in each stream flow rate in absorber

kg kg
Fy2 = 2259.6 hr Fy3 = 1740hr
H2 (%) 25.94 33.7

N2 (%) 15 19.5
CO (%) 35.96 46.7

4.2 Energy Balance
4.2.1 Energy Balance on Dryer
Heat in Rotary Drier Heat out
Heat in Heat out

 Due to feed.  With the rice husk.
 Due to air.  With the water.
Heat in with feed:
Q1 = F1 * calorific value of feed.
kg kJ
Q1 = 1800hr * 12560kg
kJ
22608000
hr
Q1 = 3600 sec
Q1 = 6280KW.
Heat in with air:
Q0 = F0 * Cp air * (T0 – T ref)
kJ
Q0 = F0 * 1kg.K * (343 – 298) K
𝐤𝐉
Q0 = 45𝐤𝐠 * F0. …………………………………………………………………………….… (12)
Heat out with rice husk:

Q2 = F2 * calorific value rice husk
kg kJ
Q2 = 1666hr * 32660 kg
Q2 = 15114.32 KW.
Heat out with water:
Cpa+Cpw
Q3 = F3 * Cp2 * ∆T, where, Cp2 = 2
kg kJ
Q3 = (F0 + 134 hr ) * 2.59kg.K * (303 – 298)

Q3 = 12.95 (F0 +0.037) …………………………………………………………………….. (13)

Total heat in = Total heat out
Q1 + Q0 = Q2 + Q3
Q3 = 6280KW + 45 * F0 - 15114.32 KW
12.95 F0 + 0.48 KW = 45 * F0 - 8834.32 KW
- 32.05 F0 = -8834.8 KW
kg
F0 = 275.65sec.
kJ kg
Then, Q0 = 45kg * 275.65sec = 12404.25 KW.
kg
From equation thirteen we get, Q3 = 12.95 (275.65sec+0.037)
Q3 = 3570.15 KW.
4.2.2 Energy Balance on Gasifier
Overall Energy Balance: The overall energy balance on the gasifier is given as follows.
Energy in + Energy Generated = Energy out ………………………………… (14)
Total Energy in: The total energy entering in to the gasifier is due to the following.
 Energy in rice husk.
 Energy in Air.
 Energy in Steam.
Energy in rice husk: Energy entering in gasifier from Biomass = F2* Cp * (Ty-T ref)
kg kJ
Energy entering in gasifier from Biomass = 1666hr * 1.926kg.K * (323 – 298) K
Energy entering in gasifier from Biomass = 22.28KW.

Energy in Air: Energy entering in gasifier from Air = Fa * Cp * (Ta-T ref)
kg kJ
Energy entering in gasifier from Air = 426.3 hr * 1kg.K * (400 – 298) K
Energy entering in gasifier from Air = 12.1KW.

Energy in Steam: Energy entering in gasifier from Steam = Fs * [Cp * (Ts – T ref) + λ]
Where, Specific heat capacity of Steam = Cp = 2.083 kJ/kg.K and Latent Heat of Vaporization, λ
= 2350 kJ/kg.
kg kJ kJ
Energy entering in gasifier from Steam = 494.82 hr * [2.083kg.K * (673 – 298) k +2350kg ]
Energy entering in gasifier from Steam = 430.4KW.

Total Energy in = Energy in Biomass + Energy in Air + Energy in Steam

Total Energy in = 22.28KW + 12.1KW + 430.4KW = 465.3KW.

Total Energy out: The total energy entering leaving out the gasifier is due to the following.
 Energy in Ash.
 Energy in Syngas.
Energy in Ash: Energy leaving gasifier with Ash = Fh * Cp * (Th-T ref). The ash leaves the
kJ
gasifier with a temperature of 1073K and the Specific heat capacity of ash is 0.514kg.K.
kg kJ
Energy leaving gasifier with Ash = 328.5hr * 0.514kg.K * (1073 – 298) K
Energy leaving gasifier with Ash = 36.35KW.

Energy in Syngas: Energy leaving gasifier with syngas = Fy * Cp * (Ty - T ref), where the
Specific heat capacity of syngas is 2.22 kJ/kg.K.
kg kJ
Energy leaving gasifier with syngas = 2308hr *2.22kg.K * (1073 – 298) K
Energy leaving gasifier with syngas = 1103KW.

Total Energy Out = Energy in Ash + Energy in Syngas
Total Energy Out = 36.35KW + 1103KW = 1139.35 KW.

Overall Energy Balance: Energy in + Energy Generated = Energy out
Energy Generated = Energy out - Energy in
Energy Generated = 1139.35 KW - 465.3 KW = 674.1KW.
4.2.3 Energy Balance on Heat Exchanger
Applying energy balance on heat exchanger
Energy in (syngas) + Energy in (Water) = Energy out (syngas) + Energy out (Water)
First calculate the amount of coolant and the outlet temperature of the coolant. In a counter-flow
heat exchanger, the temperature difference between the hot and the cold fluids will remain
constant along the heat exchanger.
Syngas (Fy) Coolant (Fc)

Heat Exchanger
Coolant (Fc) Syngas (Fy)
Fy * Cp * (Ty - Tout) = Fc * Cp * (Tc2 - Tc1)

kg kJ kJ
2308hr *2.22kg.K * (1073 –773) K = Fc * 4.18kg.K * (Tc2 – 298) K
𝐤𝐉
426.98KW = Fc * 4.18𝐤𝐠.𝐊 * (Tc2 – 298) K …………………………………...……………… (15)
The coolant leaves at a temperature of 98.55°C (Tc2 = 371.55K). The amount of water needed is
computed as;
kJ
426.98KW = Fc * 4.18kg.K * (371.55 – 298) K
kg
Fc = 4999.78hr. This is the amount of water needed per hour to reduce the temperature of syngas.
4.2.4 Energy Balance on Boiler

5 Equipment Design and Sizing

5.2 Design of Dryer
The design of a rotary dryer is better done by using pilot plant test data and the full scale
operating data of dryer of similar type if available, together with the available design equations.
A fairly large number of variables are involved such as solid to be dried per hour, the inlet and
exit moisture contents of the solid, temperature and humidity of the drying gas.
Diameter of dryer: Assume that the maximum superficial air mass velocity to be = 20000 lb/
(hr ft2).
G* area = mass flow rate of air, where, G = air mass velocity.
kg
992340
A= hr
kg = 10.16m2.
97648.55
hr.m²
ΠD2
A= ,
4
4∗10.16m2
D2 = Π
D = 3.6m.
Length of the dryer: The total heat required to remove the moisture is 3570.15KW from the
energy balance on the drier.
Q = Ua * A * L * (ΔTm), Where Ua = Overall heat transfer coefficient (volumetric) and ΔTm =
long mean temperature difference. Before that we need to calculate the overall heat transfer
coefficient from:
237(G)0.67
Ua = 3.6m
kg 0.67
237(97648.55 ) W
hr.m²
Ua = = 600.89m3 k.
3.6m
Q ∆T2 − ∆T1 20− 5
L= , (ΔTm) = ∆T2 = 20 = 10.82K.
A∗Ua∗(ΔTm) ln( ) ln( )
∆T1 5
3570.15KW
L= W = 4.995m.
10.16m2 ∗600.89 3 ∗10.82K
m k
Flight design:
Number of flights in the drier = 3 * D
Number of flights in the drier = 3*3.6 = 10.8 say 11 flights.

Radial height of the flight: The radial height of the flight taken as 1/8th of the diameter of the
drier.
The radial height of the flight = (1/8) * 3.6m = 0.45m
Drier Details:
 Drier Type: Counter Current Rotary Drier
 The material used to construct the dryer is carbon steel
 Permissible stress, 𝑓 =100.6 N/mm2 for carbon steel.
 Working pressure in the drier is 0.1013 N/mm2.
 Corrosion allowance = 3 mm.
 Joint efficiency, j = 85%
 Diameter of the drier = 3.6m
 Length of the Drier = 4.995m
 Number of Flights = 11
Thickness of the drier shell:
P∗D
ts = 2fj+P + C, Where P is the design pressure 10% excess of the operating pressure.
P = (0.1* 0.1013 N/mm2 + 0.1013 N/mm2) = 0.11143 N/mm2.

N
0.11143 ∗3600mm
mm2
ts = N N + 3mm = 2.34mm + 3mm = 5.34mm.
2∗100.6 ∗0.85+0.11143
mm2 mm2
Outer diameter: outer diameter = inner diameter + 2* ts

Do = 3600mm + 2*5.34mm = 3610.68mm.
5.2 Capacity of Hopper
The rice husk is stored in hopper right after drying.
Basis: 1 hour.
The hopper is 90% full of 1666kg dried rice husk, with allowance of 10% for safety, so the total
volume of the hopper is given as;
Volume occupied by rice husk

VT = 0.9
1666kg
Volume occupied by rice husk = kg = 13m3.
128 3
m

13𝑚3
So, VT = = 14.4m3.
0.9
5.3 Design of Gasifier
Operating Conditions:
Operating temperature = 1273 K
Operating pressure = 600 psi = 4.136 N/mm2
Volume of gasifier: Volume of gasifier = Volume of solids + Volume occupied by product gas
Chemical reactions involved in the gasifier: Chief reactions taking place inside the gasifier are;
C + CO2 2CO, fast
CO + H2O CO2 + H2, fast
C + H2O CO+H2, slow
Thermodynamic study of these reactions shows that the third reaction is the slowest step.
Therefore it will be rate determining step.
C + H2O CO + H2, This is elementary reaction. Considering the selected gasifier shows
behavior to that of a plug flow reactor.
Rate of reaction: -rA = KCA2, Where, K = rate constant and C A = final concentration.
𝐶𝐴0
∫𝐶𝐴 𝑑𝐶𝐴
Performance equation: τ = Where, τ = residence time.
−𝑟𝐴

5.4 Design of Heat Exchanger
Detail Design Information:

 Syngas is on the tube sides
 Water is on the shell side
 Flow rate of syngas= 2308kg/h.
 Flow rate of water = 4999.78kg/h.
 Inlet Temperature of syngas = 800ᵒC (1073K).
 Outlet Temperature of syngas = 500ᵒC (773k).
 Inlet Temperature of water = 25ᵒC (298k).
 Outlet Temperature of water = 98.55ᵒC (371.55K).
 Specific heat capacity of syngas = 2.22 kJ/ kg. K.
 Specific heat capacity of water = 4.18 kJ/ kg. K.
Heat Transfer Area:
First we calculate the heat load by;
Q = U*A*∆Tm, ∆Tm = ∆Tlm * Ft, Where Ft = correction factor.
The heat load, Q = Fy * Cp * (Ty - Tout) = 426.98KW
Calculating the log mean temperature difference,
(∆𝑇2− ∆𝑇1) ((1073−371.55)−(773−298) ) (701.45−475 )
∆Tlm = ∆𝑇2 = (1073−371.55) = 701.45
ln( ) ln( ) ln( )
∆𝑇1 (773−298) 475
∆Tlm = 580.94K.
The correction factor if found from the graph in which the temperature ratio meets.
𝑇1−𝑇2 𝑡2−𝑡1
R= and P = 𝑇1−𝑡1
𝑡2−𝑡1
1073−773 371.55−298
R = 371.55−298 = 4.08. P= = 0.095
1073−298
1.0
0.9
Correction factor
0.8
R = 4.0 3.0 2.0 1.5 1.0 0.8 0.6 0.4 0.2
0.7
0.6
T 1– T 2
F
0.5 R = ——–
t 0.1
– t 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

The correction factor Ft for shell-and-tube heat exchanger configurations is given in Figure
versus two temperature ratios.
Using Graph; Ft = 0.99.
So, ∆Tm = ∆Tlm * Ft = 0.99*580.94K = 575.13K.
Q = U*A*∆Tm, the overall heat transfer coefficient for water to syngas heat exchanger is
between 3-50 KJ/ ᵒC.hr.ft2. for this case we take (U = 45 W/m2 ·°C)
426.98KW
A= w
45∗ 2 ∗575.13K
m .K
A = 16.5m2.
Design Specification: The minimum information required for the mechanical design of some
important components of shell and tube exchanger is summarized below:
 Shell diameter: Shell ID 31΄ (787.4 mm); carbon steel.
 Tube outer diameter = Do = 20mm (0.02m) and internal diameter = Di = 16mm (0.016m)
 Tube length 20΄ (6.096 m as per IS: 4503-1967 and IS: 2844-1964 standards).
 Corrosion allowance: Corrosion allowance of 3 mm for carbon steel is taken as per IS:
4503 for the service in the petroleum industries.
 Permissible stress, 𝑓 =100.6 N/mm2 for carbon steel.
 Design pressure 0.38 N/mm2 ((10% higher than the operating pressure).
 Joint efficiency, j = 80%.
Number of tubes:
Area = nπDo L
16.5𝑚2
n= = 43.1. Say 43 tubes.
0.02𝑚∗6.096𝑚∗𝜋
Thickness of Shell:
P∗Ds
𝑡𝑠 = fj−0.6P + C
N
0.38 ∗787.4 mm
mm2
𝑡𝑠 = N N + 3 mm
100.6 ∗0.8−0.6∗0.38
mm2 mm2
𝑡𝑠 = 3.73mm + 3mm = 6.73mm.

5.5 Design of Cyclone Separator
Design information:
kg
 Flow rate of syngas = Fy = 2308hr = 0.64 kg/s.

 The range of optimum velocity of separator lies between 10-20 m/s (taking average, 15
m/s).
 Density of flue gases = ρ = 0.6156 kg/m3.
 Density of solids = ρs = 300 kg/m3.
Inlet Duct Area of Gas:

Fy = ρ*V*A
kg
Fy 0.64
sec
A = ρ∗V = kg m
0.6156 3 ∗15
m sec
A = 0.069m2.
Diameter of Cyclone:
A = 0.5 Dc * 0.2 Dc
0.069m2
Dc = = 0.69m.
0.1
Length of Upper Section:

Lu = 1.5 Dc = 1.5*0.69m
Lu = 0.885m.
Length of lower Section:
Ll = 2.5 Dc = 2.21m.
Outlet Duct Area of Gas:
D0 = 0.5Dc = 0.345m.
𝜋
Then, Ao = 4 *(0.345m)
Ao = 0.0935m2.
Diameter of Dust Collector:
Dd = 0.375 Dc = 0.26m.
Terminal Velocity of Smaller Particles:
kg m
0.2∗A∗D0∗ρ∗g 0.2∗0.069∗0.345∗0.6156 3 ∗9.81 2
m sec
Uo = π∗(Lu+Ll)∗Fy∗Dc = kg
π∗(2.21+0.885)∗0.64 ∗0.69m
sec
Uo = 6.7*10-3m/sec.
Particle Diameter Remove by Cyclone:
m m
18∗Uo∗V 18∗6.7∗10−3 ∗15
2 sec sec
Dp = g∗(ρs−ρ) = m kg
9.81 2 ∗(300−0.6156) 3
sec m
Dp2 = 6.1610-4m4.

DP = 0.0248m.
5.6 Design of Absorption Tower:
Assuming the operating liquid rate is 1.5 times the minimum. The actual liquid flow rate in the
absorber should be 1.5 times the minimum flow rate:
kmol kmol
L = Lmin * 1.5 = 500 *1.5 = 750 .
hr hr
Cross-sectional area of the packed tower:

The cross-sectional area of the tower is given by;
G
A = G′, Where, G = gas molar flow rate and G’ = Superficial flooding velocity.
The superficial flooding velocity is the flow rate per unit of cross-sectional area of the tower.
(∈)(ρg)(ρl)g 0.5
G’ = [ ] .
φ∗f∗µl0.2
Where;
 ρg = 1.319 kg/m3, density of syngas.
 ρl = 1022Kg/m3, density of Selexol.
 g = 9.82 m/s2, the gravitational constant.
 F = 40 ft2/ft3 (131 m2/m3), the packing factor for two- inch saddles.
 φ = 1.0, the ratio of specific gravity of the solvent to that of water.
 µl = 0.0008 Pa*s, the viscosity of solvent.
Calculating the abscissa;
𝑘𝑚𝑜𝑙
L ρg 750 1.319
ℎ𝑟
Abscissa = G √ ρl = = kmol √ = 0.135.
199.579 1022
hr
Using The Figure below, with the abscissa of 0.135, move up to the flooding line and reading the
value of ∈ on the ordinate we get∈ = 0.125.
(0.125)(1.319)(1022)∗9.81 0.5
G’ = [ ] = 7.25 kg / s. m2 at flooding.
1∗131∗0.00080.2
Cross-sectional area of the packed tower:

kg
G 2259.6
A = G′ = kg
hr
= 0.87m2.
7.25 2
s.m
Tower Diameter:
4∗0.87m2
D2 = 3.14
D = 1.05m.

Height of column:
Z = HOG * NOG
HOG = 0.61 m (From Coulson & Richardson, range is 0.6 to 1m, topic 11.14.3).
First calculating the number of transfer units, NOG; given that Henry’s law constant for the
equilibrium is 42.7.
0.59) 199.579 199.579
ln[( )∗(1−42.7 )+(42.7 )
0.00005 750 750
NOG = 199.579
(1−42.7 750 )
NOG = 5.04.
Z = 0.61m*5.04 = 3.1m.
Allowances for liquid distribution = 1m
Allowances for liquid Re-distribution =1m
Total height of tower = 5.1 m.
Specification sheet:
Identification:
Item: Absorption Column
Item No: A-104
No. required: 01
Function: To absorb carbon di oxide and hydrogen sulfide in a mixture of gases.
Operation: Continuous.

Design Data:
 No. of transfer units = 5.04
 Height of transfer units = 0.61 m
 Height of packing section = 3.1 m
 Total height of column = 11 m
 Diameter =1.05 m

6 ECONOMIC ANALYSIS
6.1 Major Equipment/Machinery Cost
SN Name of equipment Calculated size Number of equipment Cost $, Jan 2019

CE index =390.4
1 Rotary Dryer 10.16m2 1 25386
2 Hopper 13m3 1 27600
3 Gasifier 1 36534
4 Heat exchanger 16.5m2 1 2357
5 Cyclone Separator 0.69m 1 19000
6 Scrubber 1 18500
7 Absorber 1.05m 1 16415
8 Compressor 1 148642
9 Conveyor 1 21015
10 Syngas storage tank 1 104002
11 Pump 1 1917
Total 421,368


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MEKELLE UNIVERSITY

DEPARTMENT OF CHEMICAL ENGINEERING

COURSE TITLE: PLANT DESIGN AND ECONOMICS

PROJECT TITLE: PRODUCTION OF SYNGAS FROM RICE HUSK

1) Teklemariam Negash Eitm/ur83233/07

Submitted to: Inst. Gebrehiwot G. (MSc)

CHEMICAL ENGINEERING (BIOCHEMICAL ENGINEERING STREAM) Page i

CHEMICAL ENGINEERING (BIOCHEMICAL ENGINEERING STREAM) Page 1

1.2 Statement of the Problem

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1.3.1 General Objective

1.3.2 Specific Objective

The specific objectives of the study are:

1.4 Scope of the Study

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2.1 History of Gasification

Table 1 history of syngas

To produce ‘‘town gas’’ for light and heat.

2.2 Gasification process

Gasification is basically a technological process that involves the conversion of carbonaceous

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C + 0.5O2 CO -111 MJ/kmol (1)

C + H2O CO+H2 +131 MJ/kmol (4)

C + 2H2 CH4 -75 MJ/kmol (5) (5)

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Figure 1 steps gasification process

2. High Temperature Gasification: This type of gasification involves a temperature range of

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Feedstock + Limited Oxygen = CO2 + H2O + C + Associated Volatile Hydrocarbons + Heat

A major drawback of downdraught equipment lies in its inability to operate on a number of

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C. Fluidized Bed Gasifier

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Figure 2 fluidized Bed Gasifier

The gasification has the following benefits;

 Recovery and use of the bottom ash can be problematic.

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Figure 3 Rice husk

Table 2 Typical rice husk analysis [Bronzeoak, 2003]

S.N Property Range

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 Renewable source of energy.

The applications of biomass are as follows:

 Direct thermal application(such as Boiler),

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3.1 Raw materials

 Biomass (Rice Husk)

3.1.1 Biomass Selection

Table 3 composition of rice husk

3.2 Process Equipment’s

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3.3 Processes involved

1. Rice husk preparation

2. Rice husk drying

3.3.1 Rice Husk Preparation

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3.3.2 Rice husk Drying

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3.3.3 Fluidized Bed Gasification

3.3.4 Gas Cooling

3.3.5 Gas Purification

3.3.6 Carbon dioxide and Hydrogen Sulfide Removal

F1 * Xw1 = F2 Xw2 + F3 Xw3