BIOMASS GASIFICATION
FOR NATURAL GAS
SUBSTITUTION IN IRON
PLANTS
INTRODUCTION
Background
Biomass gasification plant background:
Increasing demand of iron
Limitation of gasoline, coal, LNG usage
High number of biomass production
Basic Theory
Main reaction of Iron Processing:
Iron: Main Product
Basic Theory
Biomass: biological material derived from living or rece
ntly linving organisms.
Major components in Biomass: Cellulose, Hemicelullos
e, Lignin
Year
Demand
Supply
Rice Husks
Production
capacity
Availability
Notes
Each year, rice husks production is more than
palm oil EFB
in
Indonesia
Current usage
PROCESS SELECTION
Analysis
Process
Synthesis
Mass and
Energy
Balance
Biomass Gasification
GRINDING
DRYING
GASIFICATION
Pyrolysis
Gasification
PARTICLE
REMOVAL
GRINDING
The process of
reducing the particle
size of the processed
material from the
shape of large
converted into a
smaller size
DRYING
The biomass needs to be
dried prior to gasification to
improve efficiency.
Rotary dryers are the most
common type of biomass
dryer.
In the rotary dryer, the
biomass is passed through a
rotating drum where it comes
in contact with hot gases.
GASIFICATION
Gasification is a thermal
process that breaks down
the chemical bonds in the
fuel in order to produce an
energy rich gas.
The process is an
endothermic process which
requires external heat.
Divided into two steps
Gasification
Pyrolysis
Low Temperature
Doesnt require
Oxygen
Gasification
High Temperature
Require Oxygen
REACTION
PARTIAL OXIDATION
Combustion
CO2 GASIFICATION
Endothermic
STEAM GASIFICATION
HYDROGASIFICATION
Reactor Types
Entrained Flow
Gasifier
Particle Removal
Blast Furnace
Using coal as a fuel for this process
Produce pig iron from iron ore by the r
educing action of carbon (supplied as
coke) at a high temperature
This process has a very high temperatu
re of about 1,650 C (3,000 F) that pr
oduces the liquid iron and slag
Modern blast furnaces range in size fr
om 20 to 35 m (70 to 120 feet), have
hearth diameters of 6 to 14 m (20 to 4
5 feet)
MIDREX Process
Hylsa
Iron Processing
In
0
36.3
11.8
18.9
0
0
0
0
0
0
33
66.38
0
166.38
Out
12.598
0
0
0
5.2386
7.3088
0.43255
0
71.854
1.1952
21.26
0
46.48
166.3672
Vapour
H2O
Raw Material
Cellulose
Hemicellulose
Lignin
H2O
Process
Tar
Ash
Waste
Product
CH4
Ethane
CO
CO2
H2
H2 O
Fe2O3
Fe
Raw Material
0
36.3
11.8
18.9
0
0
0
0
0
0
33
0
0
100
Drying Feed
0
36.3
11.8
18.9
0
0
0
0
0
0
33
0
0
100
Raw Material
Cellulose
Hemicellulose
Lignin
H2O
Grinder
Drying Feed
Cellulose
Hemicellulose
Lignin
H2 O
Drying
Feed
0
36.3
11.8
18.9
0
0
0
0
0
0
33
0
0
100
Gasfier
Feed
0
36.3
11.8
18.9
0
0
0
0
0
0
11.74
0
0
78.74
Vapour
0
0
0
0
0
0
0
0
0
0
21.26
0
0
21.26
Vapour
H2 O
Drying Feed
Cellulose
Hemicellulose
Lignin
H2 O
Dryer
Gasifier Feed
Cellulose
Hemicellulose
Lignin
H2O
Gasifier Feed
0
36.3
11.8
18.9
0
0
0
0
0
0
11.74
0
0
78.74
Output Gas
12.598
0
0
0
5.2386
7.3088
0.43255
34.848
17.118
1.1952
0
0
0
78.74
Gasifier Feed
Cellulose
Hemicellulose
Lignin
H2O
Gasifier
Output Gas
Ash
Tar
CH4
Ethane
CO
CO2
H2
Solid
12.60
0
0
0
0
0
0
0
0
0
0
0
0
12.60
Output Gas
Ash
Tar
CH4
Ethane
CO
CO2
H2
Particle
Removal
Ash
Solid
Syn-gas
Tar
CH4
Ethane
CO
CO2
H2
Syn-gas
0
0
0
0
5.2386
7.3088
0.43255
34.848
17.118
1.1952
0
0
0
66.14
Iron Ore
0
0
0
0
0
0
0
0
0
0
0
66.38
0
66.38
Iron
0
0
0
0
5.2386
7.3088
0.43255
0
71.85
1.20
0
0
46.48
132.51
Iron Ore
Fe2O3
Syn-gas
Tar
CH4
Ethane
CO
CO2
H2
Shaft
Furnace
Iron
Tar
CH4
Ethane
CO2
H2
Fe
Vapour
H2 O
Drying Feed
Dryer
T = 25oC
Gasifier Feed
T = 70oC
Qin
0
3,557.4
1,098.58
2,262.33
0
0
0
0
0
0
1,380.624
0
0
8,298.934
Qout
14,941.18
0
0
0
6,212.959
19,216.3
856.9681
43,490.3
28,758.24
20,366.21
0
0
0
133,842.2
Gasifier Feed
Gasifier
T = 70oC
Output Gas
T = 1200oC
Qin
0
0
0
0
2070,986
6405,432
285,656
14496,77
9586,08
6788,736
0
2738042
0
2,777,676
Qout
0
0
0
0
6212,959
19216,3
856,9681
0
120714,7
20366,21
0
0
25099,2
192,466.4
Iron Ore
Fe2O3
Shaft
Furnace
Syn-gas
T = 400oC
Iron
T = 1200oC
Energy Efficiency
Unit Operation
Energy In
Energy Out
Dryer
3,856.825
10,799.11
Gasifier
8,298.934
133,842.2
Shaft Furnace
1,777,676
192,466.4
Total
2,789,832
337,107.6
Conclusion
Biomass has great potential in Indonesia yet its added value is not widely utilized. Many solutions
are offered, in which one of the is gasification as natural gas substitution in iron plants
There are numerous sources for biomass raw material . For our plant, rice husks is used because
of many considerations like production capacity, availability, and current usage.
The gasification plant will be located in Cilegon, Banten with the production capacity of 2 million
tonnes per year.
The main processes for our plant are grinding, drying, gasification, particle removal, and reductio
n of iron ore. The technology used is entrained flow gasifier to produce high level of CO.
Simulation using ASPEN HYSYS is used in modelling the process. It is observed that H 2 and CO ar
e the most abundant component in syn-gas with the H2:CO ratio is apporoximately 1:2
It is observed that from 100 kg of biomass, 78.24 kg of syn-gas is produced. This number of syngas will be used to reduce iron ore to obtain 46.48 kg of iron.
It is observed that the mass efficiency of the plant is 78.24&, while the energy efficiency is 12%
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