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Meri-Rastilantie 3 B, FI-00980 Journal of Food, Agriculture & Environment Vol.12 (2): 831-835. 2014 www.world-food.net
Helsinki, Finland
e-mail: info@world-food.net

Performance of an updraft rice husk gasifier system for powering village rice mills in
the Philippines
Elmer Granadozo Bautista 1, Masanori Saito 2 and Manuel Jose C. Regalado 3
Rice Engineering and Mechanization Division, Philippine Rice Research Institute (PhilRice), Maligaya, Science City of
1

Muñoz, Nueva Ecija, Philippines. 2 Field Science Center, Graduate School of Agricultural Science, Tohoku University.
3
Deputy Executive Director for Research, Philippine Rice Research Institute, Maligaya, Science City of Muñoz, Nueva Ecija,
Philippines. e-mail: bautista_elmerg@yahoo.com.ph, mjcregalado@email.philrice.gov.ph, msaito@bios.tohoku.ac.jp
Received 8 January 2014, accepted 30 March 2014.

Abstract
In the Philippines, the tremendous quantity of rice husks (RH) produced by rice millers poses a variety of potentially harmful consequences to
humans and the environment. We evaluated the burning of RH in updraft gasification systems to ameliorate the problem of RH disposal and reduce
the use of other sources of energy that are usually purchased. In 2008, to assess the handling of rice by Philippine millers, we conducted a survey to
determine the number and characteristics of rice milling factories in Central Luzon, specifically in Nueva Ecija, which is among the top rice-producing
provinces. In this study, we focus on the most prevalent size of factory, which uses a single-pass mill with an average capacity of 1 t h-1 and requires
roughly 30 kW of electric power, as the type of operation that would benefit by employing was targeted to be powered by a rice husk (RH)
gasification system as a source of power. We evaluated the performance of such a system that is installed at the Philippine Rice Research Institute
(PhilRice). This system comprises a gasifier reactor (internal volume, 1.44 m3), scrubber, condensers, filter, gas storage unit, and an internal
combustion engine coupled to an electric generator. The gasification temperature ranged from 703 to 837°C, and the average temperature of the gas
entering the engine was 39°C. The conversion rate from raw RH to carbonized rice husk was 18% by weight. On average, the system generated 10-18 kW
at 173-240 V, based on a RH consumption rate of 78 kg h-1. Our results show that the generated power is insufficient to operate a rice mill processing
1 t h–1, but assessment of the operation indicates that this type of gasification system may be technically feasible if modified. The current size of the
reactor and rate of RH consumption could produce 30 kW, if the efficiency of the engine and electric generator was improved. Given these
improvements, RH updraft gasification systems might provide the electricity needed for local milling factories, using 40% of the RH material
produced during milling operations.

Key words: Electricity, engine, gasification, multi-pass rice mill, power, rice husk, rice mill, single-pass rice mill, temperature, updraft gasifier, village.

Introduction
The increasing cost and declining supply of fossil fuels have
spurred scientists to search for alternative energy sources.
Recently, rice husk (RH) gasification systems have attracted
attention as an alternative energy source in Southeast and East
Asian countries, where rice is a staple crop. China and Thailand
have led the development of several gasifier designs for industrial
applications.
Rice husk gasification is the process, whereby RH is converted
to “producer gas”, a combustible mixture of carbon monoxide
(CO), hydrogen (H2), and a small amount of methane (CH4), through
partial burning in an environment, in which the supply of air is
limited. Producer gas can be used as fuel for heating as well as for
operating internal combustion engines that power electric
generators 1, 2. The use of this technology offers several
advantages: Gasification systems operating at rice milling factories
can mitigate the problem of improper RH disposal, which
negatively impacts both the environment and human health, while
converting a considerable fraction of this biomass to useful energy,
in the form of producer gas that can power the rice mills, reducing
fossil fuel utilization and consequent resource depletion, while
lowering operation costs.
The intensive rice production in the Philippines, and the
proportionately massive amount of RH residue produced, make
the use of gasification technology especially relevant. Annually,
about 3.2 million metric tons of RH are produced by roughly ten
thousand rice millers dispersed nationwide 3. This amount of
biomass is equivalent to up to 1.7 GW-h of electricity, if used for
power generation 4, but the minimal implementation of RH biomass
to energy systems at present means that improper disposal is
ongoing (Fig. 1). Thus, development of RH gasification systems
is a promising approach to reducing the deleterious effects of RH
waste while improving the efficiency of rice production.
In the Philippines, a small rice milling factory is typically located
in each village that cultivates rice. The majority of these small
operations use single-pass milling machines that have a processing
capacity of 0.3-1.8 t h-1, which adequately meets village needs 4. A
1986 study by the University of the Philippines Los Baños showed
that the majority of rice millers use Engelberg hullers powered by
diesel engines. Shifting market demand, however, has resulted in
the adoption of small rubber roll hullers that provide higher milling
recovery 5, 6. However, regardless of the milling machine type, the
use of RH gasification systems for local generation of electric

Journal of Food, Agriculture & Environment, Vol.12 (2), April 2014 831

b Rice husk
a
Figure 1. Traditional disposal of RH in the Philippines: a) at the back
of a rice mill; b) along a roadside.
power is attractive, since it exploits a freely available and otherwise
troublesome waste material.
In 2003, a small and simple updraft RH gasification system was
installed by the New Energy and Industrial Technology
Development Organization (NEDO; under the Ministry of
Commerce and Industry of Japan) at the Philippine Rice Research
Institute (PhilRice), a government research institute located
roughly 150 km north of Manila; PhilRice works on rice-related
studies, including machine development. The system was used in
a collaborative project that explored the use of low calorific RH as
a fuel for electricity generation and production of carbonized rice
husk (CRH) as a useful byproduct of the gasification process 7.
Updraft gasifier testing shows that it is more thermally efficient
than downdraft gasifier designs, because ascending gases
pyrolyse and dry incoming biomass, transferring heat so that the
exiting gases are relatively cool (90°C) 7. Historically, the principle
of updraft gasification was widely used for coal gasification,
starting from the 1850s 8. In an updraft gasifier, the airflow direction
is the same as that of the gasses in the fire zone. Although the
operation of the PhilRice gasifier was smooth with RH input at the
top of the reactor and CRH removed from the bottom, this mode of
gasification produces large quantities of tar and smoke; so, the
resulting producer gas must be thoroughly cleaned, especially if
it is intended for use as fuel for internal combustion engines.
Although the updraft RH gasifier installed at the PhilRice
location is fully operational, it had not been used to power a rice
mill 9, despite the potential for RH gasification systems to supply
electric power for small-scale rice milling operations. The objectives
of the present work were (1) to examine the technical performance
of the PhilRice updraft RH gasification system as a possible
alternative source of energy for operation of single-pass rice milling
factories; (2) to examine the current number and distribution of
rice milling factories in Central Luzon; and (3) to discuss the
potential benefits of introducing updraft RH gasification systems
to village rice milling factories.
Materials and Methods
Updraft gasification system: The updraft gasification system
installed at PhilRice includes a gasifier reactor, a scrubber, two
condensers, a filter, a gas storage unit, and an internal combustion
engine coupled to an electric generator (Fig. 2). Seven electric
motors perform various functions when the system is operating,
requiring 3 kW of power that is supplied by the grid. Rice husk
material is loaded by a bucket elevator that lifts it to a screw
conveyor that feeds the RH into the reactor. The reactor space in
which RH gasification occurs is 1.0 m in diameter and 1.8 m high
(1.4 m3 total reactor volume). As a safety measure, two pressure
832
RH
RH 
CRH
CRH 
Producer
Producer
Water
Water 
Condenser
Filter
Reactor
elevator Waterpump
LPG fuel engine with electric Condenser Gas
generator storage
Figure 2. Schematic diagram of the PhilRice updraft gasification system.
relief outlets are provided, one at the bottom and the other at the
top lid. A regulated blower (FB-200) supplies air to the reactor,
delivering a maximum of 340 L min-1.
During the gasification process, the producer gas output by
the reactor passes through a recirculating water scrubber system,
powered by an Ebara, Japan M7 pump (requiring 1 kW at 60 Hz),
which sprays the incoming gas with water to lower its temperature
and remove particulates and tar. The cooled producer gas then
passes through a condenser and filter system that further reduces
the tar content and removes moisture, after which it flows to a gas
storage unit, a secondary condenser downstream from the storage
unit, and thence to the internal combustion engine. The flow of
producer gas is maintained by a ring blower located between the
second condenser and the internal combustion engine that powers
the electric generator. The ring blower is a 1 hp E.G. & G. Rotron
Japan-made, operating at 3450 rpm (200-230 V, 60 Hz).
The installed internal combustion engine is a four cylinders,
eight-valve 2Y model with an aerodynamic volume displacement
of 1.8 L (ISSI Corporation, Japan), and a power rating of 63 kW at
5000 rpm and 51 kW at 4600 rpm. The electric generator coupled to
the engine is a three-phase NEG-600 model (60 kVA rating) that
outputs 173 A at 200 V via a 1500 rpm brushless AC generator
(Nippon Sharyo Seizo Kaisha Ltd., Nagoya, Japan). The internal
combustion engine is first started using LPG and operated for a
few minutes before it is switched to producer gas operation.
The RH used in our operational tests was collected from the
rice milling factory at PhilRice and had 12% moisture content. The
reactor was initially started by directly loading three 12 kg bags of
RH, adding 0.5 L of kerosene, and igniting the material with flaming
pieces of paper. Additional RH was loaded when sufficient
combustion was observed inside the reactor. The startup time
interval was measured as the time from when the input RH was
ignited until electricity was generated using producer gas. The
ignition process was continued until a good fire was achieved
inside the reactor, at which time the reactor hatch was closed. The
flammability of the producer gas was manually tested by using a
lighter at a small bleeder pipe upstream of the engine intake
manifold. The engine was then slowly switched from LPG to
producer gas when the gas was readily combustible.
Temperatures in the reactor were measured with three 6.4 mm
diameter SK type thermocouples spaced 17 cm apart; the
thermocouples were capable of measuring temperatures up to
Journal of Food, Agriculture & Environment, Vol.12 (2), April 2014
950°C. Water and surface temperatures were measured with a dial- Table 1. Updraft RH gasification system operation and
type thermometer and optical pyrometer, respectively. performance data.
The electric energy output of the RH gasification system was Average
Units
measured by means of a power clamp meter, with a variable number valuea
of 1 kW incandescent bulbs acting as the load. The number of lit Operation
bulbs was used as a measure of the power output of the system. Startup time min 46
Total operation time min 128
Operational tests of the RH gasification system were conducted 8 Rice husk (RH)
times, from September 2010 to June 2012. During these operations, RH input 12 kg bags 13
the performance of the system was monitored, and the energy RH consumption rate kg h–1 78
input and output were estimated based on data gathered and CRH output (per operation) kg 28
standard energy factors from the literature. Conversion rate, RH to CRHb % 18
Temperature
Reactor temp Temp(r) ºC 780
Evaluation of Central Luzon rice milling factories: The number Gas temp (engine input) Temp(g) ºC 39
of rice milling factories operating in the Philippines in 2008 was Operating efficiency
obtained from a national survey conducted by PhilRice in Engine operationc rpm 1950
cooperation with other government agencies. The rice mills were Electric generator operationc rpm 1242
Power outputd kW 14
categorized as single-pass or multi-pass. Single-pass rice mills Generated voltagee V 173-240
have a de-husker and polisher combined in a single machine 9, Specific gasification ratef kg h-1 m-2 99
whereas the de-husker, polisher, sorter, and other components are a
Average value for eight operations; bAmount of carbonized RH produced from input RH; cMeasured
when engine was fueled by gasifier; dAverage power generated using producer gas; eVoltage measured
present as separate machines in multi-pass mills. Milling factories from generator output; fFeed rate of RH per hour per unit area of the reactor.
with capacities greater than 5 ton h-1 were classified as commercial
factories. Data were analysed according to factory size and operation. The CRH was uniformly black in appearance, indicating
distribution among provinces. that gasification conditions were appropriately maintained during
In 2012, the author visited 5 representative small rice mills in operation. The average temperature inside the reactor was 780°C,
Nueva Ecija province, Central Luzon, and factory foremen/workers well within the allowable temperature range for RH gasification.
were interviewed using a questionnaire. Information such as rice Although we did not measure the composition of the resulting
mill capacity, size of prime mover, rice husk disposal practices, producer gas, a previous study 10 using the same updraft RH
and other related information, was recorded, and a typical single- gasification system operated with the same feedstock and same
pass rice mill installation is shown in Fig. 3. condition showed that it is composed of 15-20% CO, 5-7% H2, and
1-3% CH4, and has a caloric value of 4000 MJ m-3.
One cubic meter of water was used during each session of RH
Elevator
gasifier operation. This includes water for the scrubber that cools
the hot producer gas exiting the reactor and removes impurities,
water for the condensers and filters, and water in safety buckets
for pressure relief at the reactor. The producer gas was ultimately
Stone remover De-husker cooled to a safe temperature for input to the internal combustion
engine. The average water temperature in the scrubber was 39°C;
the initial water temperature of 28°C increased to 42°C at the end
of the operation. We observed that with 600 L of water used at the
Polisher
scrubber cooling system, 7 L of tar (1.17%) were collected during
Bagger the spray-cooling process. The generator rotated at a calculated
average of 1242 rpm. The rate of rotation was correlated with the
output voltage, with faster rotation resulting in higher output
voltage, but increasing the electric load, by increasing the number
of incandescent bulbs in the circuit, slowed the rotation and lowered
the voltage.
Operation of the updraft RH gasification system requires the
Figure 3. Single-pass village rice mill in Nueva Ecija province, Central Luzon. input of energy in several forms, and yields energy in the form of
generated electricity and waste products (Table 2). Energy input
Results was provided in the form of RH (1084 MJ h-1), electricity to power
Updraft RH gasification system performance: We operated the motors (35.7 MJ h-1), water (0.1 MJ h-1), kerosene (2.9 MJ h-1),
PhilRice updraft RH gasification system 8 times, with an average lubricant (4.5 MJ h-1), and LPG (11.5 MJ h-1). Total energy output
operation time of 128 min, excluding the 46 min average startup of 313.4 MJ h-1 was obtained as generated electricity (166.6 MJ h-1),
time (Table 1). Electricity was generated throughout the operation CRH (113.6 MJ h-1) and tar (32.4 MJ h-1). The gasification efficiency
time, until the expected volume of RH was consumed. With an for the generation of electricity was 14.6%, a value within the
average RH input of thirteen 12 kg bags and a consumption rate range of those obtained in previous research 7. The low efficiency
of 78 kg h-1, the voltage range of the generated electric output was of the gasification system might be due to the age of the engine-
173-240 V and energy output was 10-14 kW. The CRH conversion generator set.
rate was 18% of RH input, with an average of 28 kg produced per Our results indicate that the power output of the PhilRice updraft

Journal of Food, Agriculture & Environment, Vol.12 (2), April 2014 833
 Table 2. Energy input/output during RH gasification.
Material Amount Input Energy (unit) Energy (MJ h-1)
RH 78 kg h-1 12.8 MJ kg-1 11 1084
Electricity for gasifier 3 kW 111.9 MJ kWh-1 12 35.7
Gasifier
Water for gasifier 1 m3 in 8 h 0.6 MJ m-3 12-14 0.1
Kerosene 0.5 L in 8 h 46.3 MJ L-1 15 2.9
Water for engine 1 gal h-1 0.6 MJ m-3 12 0.003
Enginegenerator set Lubricants/Oil 0.1 kg h-1 per wk 35.9 MJ kg-1 15 4.5
LPG 2 kg per 8 h 46.1 MJ kg-1 15 11.5
Total input 1138.7
Output
CRH 13.3 kg h-1 8.5 MJ kg-1 16 114
Gasifier
Tar 7 L (1.17% of 600 L H2O) 36 MJ kg-1 17 32.4
Enginegenerator set Electricity 14 kW 11.9 MJ kWh-1 12 167
Total output 313.4

RH gasification system is inadequate to operate small-scale (~1 t h–1)
rice milling factories that typically require 30 kW. Provision of this
amount of power will require a RH gasification system that
incorporates an improved design, is operated under improved
conditions, or both.
Current status of rice milling factories in Central Luzon: In rice
producing areas in the Philippines, local dealers and farmers store
their rice unmilled and bring it to a local factory for milling as
needed. Data from 2008 indicate that, among 25,906 rice milling
factories in the Philippines, more than 95% (24,980) are equipped
with a single-pass rice mill. In Central Luzon, which accounts for
18% of the country’s total rice production 3, roughly 12% of
factories were equipped with multi-pass rice mills, i.e. 255 factories
out of 2165 (Fig. 4). In Nueva Ecija province, which in 2008
accounted for 46% of the region’s production, 515 small-scale rice
mills had an annual milling output of 387,538 metric tons. The
single-pass and multi-pass rice mills located in Nueva Ecija were
about 24% and 54% in Central Luzon, respectively. Most RH
produced by the village factories servicing local farmers and rice
dealers is dumped and burnt elsewhere, circumstances that are
typical among the highest rice-producing provinces in the
Philippines.
Most rice milling factories with single-pass mills (including the
PhilRice facility) use automotive engines or electric motors to
provide approximately 30 kW of power needed for operation. A
typical factory’s main components and their power requirements
include the following: Huller and whitening machine (15 kW),
1,400
1,200
Number of unit
loading system (5 kW), and de-stoning machine (4 kW). Such rice
milling factories have an average capacity of 5-7.5 tons per day,
processed during 5-10 hours of operation.
During the interviews we carried out locally, we learned that
millers operate daily at the request of customers mostly residing
in the same village, and charge an average of 0.05 USD per kg of
milled rice. The average milling recovery rate was 62% but actual
values depend on the quality of the unmilled rice. Part of the RH
produced as a milling by-product is given away for local household
use, and some is sold (at 0.025 USD per kg) to duck husbandry
operators for use as bedding (litter).
Discussion
Most rice milling factories in rural areas of the Philippines are
small, employ a single rubber roll huller and whitening machine,
have a milling capacity of roughly 1 t h-1, and require about 30 kW
of electric power for operation, including lighting. Given the small
scale of these facilities, small engines or electric motors are
sufficient. The size of the current updraft rice husk gasifier system
is practically fitted to such small single-pass rice mills because
the feeding rate of 78 kg h-1 rice husk may produce 28-46 kW
electricity 18. The electric power output of the tested PhilRice
gasification system, however, attains less than half the 30 kW
requirement. Technical evaluation of the reactor shows that the
energy available from gasified rice husks inside the reactor is
enough to generate bigger power output. Adequate provision of
rural milling factory power requirements using RH gasification
systems therefore may require increased component capacities. It
is assumed that changing the present LPG engine to
bigger power rating will produce more electricity.
However, some parts of the rice husk gasifier system
need to be modified to cope with the changes.
Assuming a 1.0 t h-1 processing capacity, a typical

1,000 rural rice milling factory can produce up to 1600 kg of

800 RH daily, or 480 t y-1. The PhilRice gasifier consumes 78 kg
600 h-1 rice husk, which is 187.2 t y-1. The gasifier system uses
400 40% of the rice husk produced by typical rice mill
200 factories, which contains enough energy to generate
Rice production
0 (x1000)
the required power for a small rice mill factory. Further
o r a
an Multi-pass enhancement of the system could produce additional
ur ta n
A Ba a ca cja
a rice mills power not only for the rice mill itself but also for
l
Bu
E ng rla
c
es
eva pa a al households. Since the gasifier system was only assumed
u m T b
N Pa m
Za to operate 8 h d-1, the remaining rice husks (60%) could
Figure 4. Rice production volume and number of rice mill factories for provinces in
be used to continually operate the system for domestic
Central Luzon (2008). electric consumption and other uses.

834 Journal of Food, Agriculture & Environment, Vol.12 (2), April 2014
 Utilization of RH gasification systems can reduce RH disposal
costs, and lessen the negative impact upon the environment and
human health caused by open-air burning of RH. RH at rice mill
factories will be valued owing to the RH gasification processes.
With current output of 14 kW, the process can generate 372 GJ y-1,
equivalent to 62.8 ton CO2 eq. y-1 emission savings.
If the updraft RH gasification systems is utilized for power
generation in Nueva Ecija province rice milling factories, it can
utilize an otherwise problematic byproduct of rice cultivation, i.e.
the roughly 1237 tons of RH annually produced. This amount is
enough to generate sufficient electricity for the province’s rice
milling operations. At the national level, the Philippines could
make use of the roughly 1.2 million tons of RH produced annually,
as a valuable fuel source for gasification systems. Furthermore,
approximately 18% of the RH input to gasifier reactors is discharged
as CRH, a carbonaceous material of considerable utility. This
biochar is recognized as a particularly attractive material for soil
amendment. The application of CRH to arable soils not only
improves crop growth, it also provides superior carbon
sequestration than does its use as a secondary fuel 19.
Conclusions
Updraft RH gasification systems can be used to generate all or a
portion of the electric power required for the operation of small-
scale rice milling factories in Central Luzon, the Philippines. Such
systems consume a rice milling byproduct produced in huge
volumes; other disposal options are problematic. The CRH biochar
produced by gasification is attractive as a nutritious soil additive.
However, fully meeting the power needs of such factories will
depend on improved system designs that provide higher RH
processing capacity and more electric power than the PhilRice
system tested in this study. Given further development and broader
adoption, such systems may boost the efficiency of local rice
production while decreasing harmful environmental consequences
of RH disposal.
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Acknowledgements
The authors are deeply grateful to NEDO and PhilRice for
allowing them to operate the updraft RH gasification system over
an extended period of time, and to the JSPS Ronpaku Fellowship
Program. We also thank the National Food Authority and the
Philippine Center for Postharvest Development and Mechanization,
and the various rice mill owners who provided valuable
information.

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