BioMax 25 Power System

1
BioMax 25 Power System

• System Overview and Training

2
Systems Engineering

• Mechanical
• Electrical
• Chemical
• Structural
• Computer
• Process Control

3
System Overview

• Gas Cleaning
• Power Generation

• Fuel Conditioning
• Gasification
• Gas Cooling

4
System Components

• Components
• Drying Bins
• Horizontal Auger
• Sorting Screen
• Fuel Feeder
• Gasifier
• Heat Exchanger
• Filter
• Control System
• Engine/Generator

5
Gasifier

• 5 zones
• Fresh Feed
• Final Drying
• Flaming Pyrolysis
• Char Oxidation
• CO2 Heat
• Char Reduction
• CO H

6
Gasifier (cont.)

• Char Air Subsystem
• Secondary air injection into the gasifier to
  control the temperature of the gasifier
• 5 levels of air injection
• 5 control valves
• 1 air blower
• 30 air injection fingers
• Temperature Measurement
• 12 thermocouple measurements in the gasifier
• Redundant thermocouples in the char air zone
• Dp (Differential Pressure) Measurement
• Gasifier and Grate dp

7
Gasifier (cont.)

• Grate Subsystem
• Located near the bottom of the gasifier
• Pushes ash and charcoal through the screen at the
  bottom of the gasifier
• Responsible for maintaining a low gasifier and
  grate resistance and to help mitigate a high
  flame front
• Vibrator Subsystem
• Located under the feed gate at the top of the
  gasifier
• Breaks up rat holes and prevents fuel bridging
  problems
• Automatic Ignition
• Cal rod resistive heater
• Located near the bottom of the gasifier near the
  grate subsystem

8
Gasifier (cont.)

• Gaskets and Seals
• 2 gaskets on the gasifier
• 1 thermiculite gasket at the flange
• 1 silicone gasket on the cleanout port to the
  HEX.
• Main gasifier flange
• 12 bolts
• Hydraulic lifting mechanism

• Insulation and Shell
• Gasifier is covered in 6 of ceramic insulation
• Insulation is covered by a metal shell
• Maintenance Port
• Located on the opposite side of the heat
  exchanger
• Insulation cover must be removed to expose the
  flange

9
Heat Exchanger

• Shell and Tube
• Producer Gas travels through the tubes
• 24 tubes move independently of each other
• Cooling air is circulated around the shell
• Reduce producer gas temperature from 700C to
  110C (1,292F to 230F).
• Gas Cooling Blower
• 5hp motor
• On/Off and speed controlled with a motor
  controller
• Clean-out port located on the gasifier

10
Filter

• Self Cleaning Bag Filter
• 4 cell filter
• Weights tied to the top of each bag
• Automatic char and ash removal system
• Safety filter downstream
• Rupture disks for each filter and the char drum
• Only 3 filters active at any one time One
  filter is always in cleaning mode Filter is
  shutoff with a inline valve
• O2 measurement
• Detects air leaks
• Producer gas flow meter
• Venturi meter
• Filter Enclosure
• Cooling Fan on/off controlled with a thermostat
  located in the filter junction box
• Preheat
• Strip Heaters
• Responsible for heating the filter enclosure
  above producer gas condensation point before
  gasifier ignition

11
Control System

• Programmable Automation Controller (PAC)
• Compact Field Point
• 1 control module and a variety of I/O modules
• Can be connected to the internet or a LAN
• All incoming data is recorded and stored
• Automatic control and monitoring system
• Automated alarms, responses, and shutdowns

12
Control System (cont.)

• Sensors
• Thermocouples
• Pressure Transducers
• Air Leak O2 Sensor
• Venturi Flow Meter
• Gasifier Feed Level Sensor
• Feed Gate Open and Closed limit switch
• Motor Controllers
• Used to vary the speed of various motors
  throughout the system

Thermocouple
Pressure Transducer
Motor Controller
13
Engine/Generator

• Commercial Gillette Engine/Generator Set
• GM V-6, 3.1 Liter, Vortec Engine
• WEG 35kW Generator
• Roots Blower
• In-line producer gas blower
• Provides gas flow to the flare while the engine
  in not operating or provides flow to the flare
  when the engine is not operating at full load

14
Engine/Generator (cont.)

• Modified Engine
• In-line gas blower
• Automatic Engine Starting
• Control system controls the A/F ratio with the
  use of an O2 sensor
• Generator
• Can run in stand alone or utility parallel
  configuration
• 25kW Max continuous power

15
Flare

• Used to burn excess producer gas
• Located on the top of the trailer
• Hot surface igniter
• Thermocouple
• Flare Failure
• Dangerous CO gases
• Clear to Blue flame

16
Operating the BioMax 25 System (Overview)

• Embedded Control Code
• 60 seconds boot-up cycle
• Wait for LED B on the control module to begin
  blinking
• Pre-run checklist
• Start and Pre-heat
• Normal Operation
• Alarms
• Shutdowns
• Operational Tasks
• Turn on 120VAC inverter to power the control
  system.
• Respond to alarms

17
Operating the BioMax 25 System(Pre-Run Checklist)
Tabs

• Navigate through the different control screens by
  clicking on the tabs at the top of the control
  screen.
• Before Starting a run Pre-run Checklist
  Select the Pre-Run Checklist tab
• Each item on the checklist must be completed and
  checked off before a new run can start

18
Operating the BioMax 25 System(Starting the
System)

• Starting the System Select the Inputs tab
• Start button lockout
• If Pre-run checklist is not complete
• If the Start button is pressed the systems
  enters pre-heat mode
• Feed gate latch is active, Gas Cooling blower,
  Filter pre-heaters, and Heat Exchanger
  pre-heaters are turned on
• Run until Filter Out temperature gt producer gas
  condensation point (40C)
• 15 to 20 minutes

19
Operating the BioMax 25 System(Normal Operation)

• Normal Operation
• Outputs tabs
• Displays the current status all motors, valves,
  and other electrical devices
• Automatic/Manual Control
• Automatic Ignition after pre-heat is complete
• Fresh fuel feeding after gasifier temperatures gt
  800C
• Outputs Vars tabs
• Can only be accessed with password
• Contains all set-points and control parameters
• Changing values on the Output Vars tabs can
  cause the system to become unstable

20
Operating the BioMax 25 System(Indicator Lights)

• Indicator Lights
• Computer display lights
• Green light
• Solid Run in process no alarm conditions
  present
• Blinking Run in process Operator alert
  Condition
• Yellow light
• Solid Controlled Shutdown Started
• Blinking Run in process Yellow Alarm
  Condition
• Red light
• Solid Emergency Shutdown
• Blinking Run in process Red Alarm Condition

21
Operating the BioMax 25 System(Control Buttons)

• - Green Button
• Start new run
• Can only be initiated from Emergency Shutdown
  State
• Yellow Button
• Start Controlled Shutdown
• Can only be initiated from Normal Operating State
• Red Button
• Start Emergency Shutdown
• Can be initiated at any time
• Blue Button
• Start System Purge
• Can only be initiated from Emergency Shutdown
  State
• Gasifier must be lt 200C
• Purple Button
• System Maintenance

22
Operating the BioMax 25 System(Retrieving System
Data)

• Connect a computer to the control system
• FTP Protocol Internet Explorer
• d/ni-rt/Labview Data/Run Date
• Spreadsheet program
• 97 full

File Path
Data Files
23
Operating the BioMax 25 System(Operational Tasks)

• Filter
• Empty Char Bin of char fines
• About once a week(40 hours)
• Gasifer
• HEX
• as need depending on feed

24
Maintaining the BioMax 25 System(Overview)

• Maintenance
• Required for safe and efficient operation
• Every time the system is shutdown because of a
  controlled or emergency shutdown a maintenance
  task must be completed.
• Dangers associated with maintenance tasks
• Heat/burn hazards
• CO hazards
• Particulate hazards

25
Maintaining the BioMax 25 System(Purge Procedure)

• Before opening any part of the BioMax 25 system
  for any reason the system must be PURGED!!!!
• Purging the system will
• Eliminate dangerous CO gases
• Prevent explosion hazards
• Can not purge the system until
• System has been at rest for 12 hours
• Gasifier temperatures are all lt 140C
• Stop the purge cycle immediately if Gasifier
  temperatures start to rise.

26
Maintaining the BioMax 25 System(Gasifier
Maintenance)

• Reasons to Service the gasifier
• Excessively High Pressure Drop
• Cal Rod Failure
• Grate Failure
• Clogged Air Holes
• Air Leak
• Remove Insulation Cover
• Remove flange bolts
• Lift gasifier with hydraulic lift

Deflector cone
Flange
Rock,Clinkers and junk
Grate TC
27
Maintaining the BioMax 25 System(Gasifier
Maintenance cont.)

• Remove char and ash clinkers
• Remove the grate to clean the mesh material
• Inspect the gasket
• Inspect char air injection fingers

28
Maintaining the BioMax 25 System(Heat Exchanger
Maintenance)

• Reasons to service the Heat Exchanger
• Excessively High Pressure Drop
• Poor gas cooling performance
• Remove gasifier side clean out port cover
• Remove heat exchanger out flange
• Use a vacuum and cleaning rods
• When re-assembling the heat exchanger flanges
  inspect the integrity of each gasket.

29
Maintaining the BioMax 25 System(Filter
Maintenance)

• Reason to service the Filter or safety filter
• Excessively High Pressure Drop
• Remove each upper filter drum
• Detach weights from bags
• Remove hose clamps that secure bags in place
• Install new bags
• Slick side of bag goes in first
• Reinstall weights
• Check each safety filter
• Replace filter bag if a safety filter is fowled

Dirty Filter Bag
Clean Filter Bag
30
Maintaining the BioMax 25 System(Thermocouple
and Pressure Port)

• Thermocouples
• Open thermocouple
• False Junction
• Pressure Ports
• Clean ports with a drill bit
• Check pressure tube integrity

31
Maintaining the BioMax 25 System(Engine
Maintenance)

• Follow instructions in Engine Manual
• Change engine oil every 150 hours
• Check the engine coolant

32
Health and Safety

• Hazards
• High Temperature Hazards
• Particulates
• Electrical
• CO
• Explosion Hazards
• Flame and Smoke
• Moving Parts

High Voltage
Poison Gas
33
Health and Safety (cont.)

• High Temperature Hazards
• Burn hazards include
• Gasifier
• Heat Exchanger
• Hot water hose
• Engine
• Avoid hot surfaces while operating
• The longer you run the hotter it gets
• Protective Clothing
• Gloves

34
Health and Safety (cont.)

• Particulate Hazards
• Char and Ash particulates
• Small
• Explosive
• Only way to prevent particulate inhalation
• Wear a particulate rated face mask while
  performing maintenance
• Use HEPA rated vacuum
• Do not use HEPA rated vacuum for any other
  cleaning
• Char and Ash Particulates are located
• In the Gasifier
• Heat Exchanger
• Filter and Filter Char Bin

35
Health and Safety (cont.)

• Electrical Hazards
• 3 phase 480VAC, 1 phase 120vac
• (480vac, 120vac) Breaker Box located next to Main
  Control Box
• DC Control Box
• All 3 phase AC voltage delivered by the generator
  Turn off main generator breaker to kill 3 phase
  power
• 120vac power delivered from 12vdc battery and an
  inverter
• 120vac is available even if the engine is not
  running!
• Use Safe electrical practices around the BioMax
  system
• Always use a meter to verify voltage is not
  present before working on a circuit

• DC Voltage
• Turn off DC Box breaker in Breaker box to kill
  24vdc power supply
• 12vdc battery in engine enclosure
• Acid
• Eye Protection
• Protective Clothing
• Explosive gases
• Good Ventilation

36
Health and Safety (cont.)

• CO Hazards
• Colorless
• Odorless
• Poisonous
• Combustible
• How to detect CO?
• CO Monitor
• Hand Held
• Wall monitors
• Symptoms of CO Poisoning
• Headache
• Fatigue
• Shortness of breath
• Nausea
• Dizziness
• Large quantities of CO can KILL
• Effects of CO poisoning can be irreversible

• What to do if you suspect CO poisoning
• Vacate the area
• Ensure proper ventilation around the system
• Engine Exhaust
• Preventing CO Poisoning around the BioMax 25
• Purge the system before any maintenance or
  opening any vessel
• Ensure proper ventilation
• Keep the feed gate closed until a new run is
  started or the system has been purged

37
Health and Safety (cont.)

• Explosion Hazards
• CO and Particulates
• O2 leak into the BioMax 25 system could cause and
  explosive mixture
• O2 sensor in system to detect an explosive
  mixture
• Over 6 Oxygen is explosive
• Hot charcoal can supply an ignition source
• No spark is needed if gas is extremely hot
• Flash Point
• Feed Gate
• Gravity powered feed gate
• Emergency Shutdown will release the feed gate

• Feed Gate (cont.)
• If Feed gate does not close on shutdown
• Smoke out the top of the gasifier is combustible
• Do not try and fix feed gate
• Ventilation system is designed to keep the levels
  of smoke escaping the gasifier below explosive
  levels.
• Rupture disks to prevent catastrophic failure
• Locations
• 1 for each filter
• If a rupture disk fails
• Cover the opening
• Use a CO monitor
• Begin an emergency shutdown

38
Health and Safety (cont.)

• Flame and Smoke Hazards
• Top of Gasifier
• Smoke can burst into flames
• Moving Parts
• Gasifier Feeder
• Chain drive
• Feed Gate
• Filter augers
• Fans
• Filter enclosure
• Engine radiator
• Engine enclosure
• Dryer

• Tripping/Falling
• Keep the area clean