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<DIV><FONT face=Arial size=2><STRONG>Hi Gasification
Colleagues,</STRONG></FONT></DIV>
<DIV><STRONG><FONT face=Arial size=2></FONT></STRONG> </DIV>
<DIV><STRONG><FONT face=Arial size=2>As we are almost to the end of another
year, it's timely to bring you the Fluidyne Update on our gasification
development programme being conducted in California. Apart from the
development programme, there are many other project issues of infrastructure
support needed for successful implementation of medium scale industrial
gasifiers, so substantial time and resources have been allocated during
this past year to researching a match for specific scenarios. The year has
passed much to quickly!</FONT></STRONG></DIV>
<DIV><STRONG><FONT face=Arial size=2></FONT></STRONG> </DIV>
<DIV><STRONG><FONT face=Arial size=2><U>Visitor to New
Zealand</U>.</FONT></STRONG></DIV>
<DIV><STRONG><FONT face=Arial size=2></FONT></STRONG> </DIV>
<DIV><STRONG><FONT face=Arial size=2>A visit on 10th October
from my long term friend of the Producer Round Table days, was Ludo
Larcross, now living in Thailand for the past 20 years, and heavily
involved with biomass energy projects. We spent a few hours talking gasifiers
down my back shed, running the Pioneer Class gasifier I have set up, and
discussing the prospects of bringing many of our old colleagues together again.
All of them represented their countries Institutions or Aid Agencies, and were
responsible for initiating many of the gasification studies and projects during
1970's and 80's . I know some will welcome the chance to catch up
Ludo, so should drop me an email if you read this
posting.</FONT></STRONG></DIV>
<DIV><STRONG><FONT face=Arial size=2></FONT></STRONG> </DIV>
<DIV><STRONG><FONT face=Arial size=2><U>Latest Testing in
California.</U></FONT></STRONG></DIV>
<DIV><STRONG><FONT face=Arial size=2></FONT></STRONG> </DIV>
<DIV><STRONG><FONT face=Arial size=2>The test programme for the long awaited
MK10 Andes Class gasifier took place from 5th-22nd November, bringing a
significant change to how the gas is made. Actually, while the basic work
platform of coolers, filters, and condensers of the Andes Class programme was
reused, the gasifier itself is new, and of linear design. We refer to it as
"Linear One" for a working title. </FONT></STRONG></DIV>
<DIV><STRONG><FONT face=Arial size=2></FONT></STRONG> </DIV>
<DIV><FONT face=Arial size=2>
<DIV><STRONG><FONT face=Arial size=2>The MK9 Andes Class round hearth
design, was during 2011, pushed to the limit of it's gas making capability, just
reaching a wood conversion of 270lbs/hr (120kg/hr) which roughly equates with
1.2 million btu's for process heat, or 100 kWe if generating engine powered
electricity. In actual fact, this design was more stable around 75% of this
output, but provided a capability to study how the fuel behaves, moving at high
bed speeds, within changing parameters to maintain a tar free gas making
capability. </FONT><FONT face=Arial size=2>They </FONT></STRONG></DIV>
<DIV><STRONG><FONT face=Arial size=2>chipped just over 400 tonnes of logs
for these test, which puts real meaning into processing a forest
through the small 7" funnel </FONT><FONT face=Arial size=2>of a gasifier
throat.</FONT></STRONG></DIV>
<DIV><FONT face=Arial size=2></FONT> </DIV></FONT></DIV>
<DIV><STRONG><FONT face=Arial size=2>The new linear gasifier is contained in a
flat sided casing, with a fuel feeding auger sticking out of it's rear, heated
to around 300C by the exiting gas. This lower output gas temperature
has already made redundant the primary gas cooler of the Andes componentry,
allowing for a more compact and versatility of assembly options. The feed auger
connects to the existing fuel locks and drier/elevator system, and the two gas
outlets plug into the Andes component platform with flexibles. This will be
easier to understand when I post the project photos on the Fluidyne Archive,
which is now back at it's old site <A
href="http://www.fluidynenz.250x.com">www.fluidynenz.250x.com</A> These
will be available in about a week or so.</FONT></STRONG></DIV>
<DIV><STRONG><FONT face=Arial size=2></FONT></STRONG> </DIV>
<DIV><STRONG><FONT face=Arial size=2>Due to the size of the existing gas
cooling/cleaning system, the output from the new gas making hearth was made for
the same 1.2 million btu gas production, but with such changed
parameters, felt quite nervous as to how this design would perform. As it
turned out, the output increased by 6%, waste char reduced to about 2% (down
from 4%) and the gas quality only slightly fluctuated right through
the range of flows tested. These were measured at 100, 108,
124,147,155, scft/minute. At maximum output, we saw CO 26%, H2 15%, and CO2
11%, but CH4 readings were found to be faulty due to a problem of the sensor
calibration. The analyser is to be returned to the manufacturer and reset
specifically for CH4, and a second unit ordered as a back-up for the
2012 continuously operating test programme beginning in February, when the
heating system is required.</FONT></STRONG></DIV>
<DIV><STRONG><FONT face=Arial size=2></FONT></STRONG> </DIV>
<DIV><FONT face=Arial size=2><STRONG>After the first successful test run, an
inspection was made of the internal metal and refractory, looking for any
distortion to the components, as the oxidation temperatures were higher than
previously experienced during this development programme, measured at 1,350C in
a safe TC position just out of the oxidation lobes. As almost the whole system
is automated, the gasifier was restarted for a continuous 24hr test for the
second run, but manual draining of the aqueous condensate was required about
every six hours. This amounted to roughly 10 gallons (40 litres) each drain, an
increase over previous tests, highlighting how climatic seasonal conditions
influence and change a gasifiers performance. It takes no
imagination to see how this much water would affect the engine or burner
performance, if not removed from the gas stream.</STRONG>
<DIV><FONT face=Arial size=2><STRONG></STRONG></FONT><FONT face=Arial
size=2></FONT> </DIV></FONT></DIV>
<DIV><STRONG><FONT face=Arial size=2>Although set-up in February 2011, the large
Cyclomix burner assembly and heat exchanger had not been used for last Winters
heating trial, due to other business demands for the time available, but was
ready for use for this latest test programme. A refractory felt lining was
installed into the combustion chamber, and a pile of refractory brick mounded in
front of the blue flame, creating an incandescent radiating mass. It can be said
now, that with the gas making quality stabilized, very accurate emission tests
could be conducted on the flue gas. All these tests were conducted by Tom Miles,
who has patiently waited in the wings for us to bring it all together, and
see if we could meet those standards he measures. His written report
hasn't reached me yet, but he was pleased at the outcomes, and looking forward
to measuring the Tecogen CHP system in 2012 on the new
gasifier.</FONT></STRONG></DIV>
<DIV><STRONG><FONT face=Arial size=2></FONT></STRONG> </DIV>
<DIV><STRONG><FONT face=Arial size=2>From a personal perspective, these latest
trials were in my opinion, some of the best producer gas that I have ever seen
during the 35 years of working with this gas. Two years ago, it was established
that in this location, producer gas could replace LPG for around 60% cost wise.
LPG costs this past year are up 50% over last year, so the economics are
swinging well over into credits for producer gas. As a project initiated to
replace LPG, bringing stability to the heating costs for this Forestry
Nursery, it is very satisfying to see a project reach it's objectives. This
coming year of 2012 is when it all comes together, so for us all involved, it's
"steady as she goes" !!</FONT></STRONG></DIV>
<DIV><STRONG><FONT face=Arial size=2></FONT></STRONG> </DIV>
<DIV><STRONG><FONT face=Arial size=2><U>Automated engine gas
control.</U></FONT></STRONG></DIV>
<DIV><STRONG><FONT face=Arial size=2><U></U></FONT></STRONG> </DIV>
<DIV><STRONG><FONT face=Arial size=2>Trials with the Tecogen on producer gas
were put on hold, until I returned for these latest tests. Using the old Onan
generator, we had to develop an automated starting sequence of gas mixture
control, requiring a rather unusual fabricated assembly. Not quite a mixer, but
a signal generator for the gas regulating supply valve. After a few false starts
to get the programming right, the engine was able to start-up and run quite
smoothly. Time ran out for me to swap the system over to the Tecogen, but they
assured me it would be fitted in time for the February
trials.</FONT></STRONG></DIV>
<DIV><STRONG><FONT face=Arial size=2></FONT></STRONG> </DIV>
<DIV><FONT face=Arial size=2>------------------------</FONT></DIV>
<DIV><FONT face=Arial size=2></FONT> </DIV>
<DIV><STRONG><FONT face=Arial size=2>Finally, the large IHC engine used for the
Laimet</FONT></STRONG> <STRONG><FONT face=Arial size=2>Chipper threw a con
rod, just a few days before I left on 22nd November. A replacement engine
has been located, and in the fullness of time, be built into a new transportable
trailerized assembly. In the mean time, testing has commenced on using a wide
range of standard wood chips available from local contractors. The new linear
hearth is fully and easily adjusted, so these tests will be to establish a clear
boundary for fuel quality. Having had a chance to see these chips, it is clear
that quality control is not a factor for many of these suppliers, and fines make
up a large proportion of these piles. </FONT></STRONG></DIV>
<DIV><STRONG><FONT face=Arial size=2></FONT></STRONG> </DIV>
<DIV><STRONG><FONT face=Arial size=2>Hope this has been of interest for
you.</FONT></STRONG></DIV>
<DIV><STRONG><FONT face=Arial size=2></FONT></STRONG> </DIV>
<DIV><STRONG><FONT face=Arial size=2>I take this opportunity to wish you all an
enjoyable Festive Season.</FONT></STRONG></DIV>
<DIV><STRONG><FONT face=Arial size=2></FONT></STRONG> </DIV>
<DIV><STRONG><FONT face=Arial size=2>Doug Williams</FONT></STRONG></DIV>
<DIV><STRONG><FONT face=Arial size=2>Fluidyne
Gasification.</FONT></STRONG></DIV>
<DIV><STRONG><FONT face=Arial size=2></FONT></STRONG> </DIV>
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