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About Producer Gas Plant

Many industries were using Producer Gas as a cheap Gaseous Fuel since Mid- Nineteenth Century. Producer Gas was generated from the reaction of Air and Steam with Coal in single-stage generators either made of bricks in the initial

stages or steel with water jacket or refractory lining in the later versions. Before extensive production of Natural Gas and other Petro-fuels at a moderately lower cost, Producer Gas had been a versatile fuel owing to several advantages over the solid fuels , viz, ease of production, better thermal efficiency in the application, ease of control, smoother flame etc. As a result many industries all over the world have been using Producer Gas as a cheaper energy in various field of applications viz, glass and ceramics, Refractory, Lime-kilns, Dryers, Heating furnaces, etc but with limited flame temperature up to 1000° to 1100°C.

But the Producer Gas in earlier 19 th Century from conventional Single Stage design had several disadvantages. In these gasifiers Producer Gas used to come from one side at the top of the gasifier at a temperature of 470°C to 500°C resulting in the following disadvantages:

  1. As the gas was coming out from one side of the Producer, there will be always a preferential flow which will not permit the old coal bed to come under gasification reaction resulting in poor quality of gas.
  2. Because the coal bed is not coming under reaction, there will be not adequate reduction reaction which will cause a high temperature at the outlet gas of the producer and causing thermal cracking of the coal tar which will form soot and gumming materials and will get deposited in the pipe line. Due to this cracking of coal tar and deposit of soot, the pipe line gets frequently chocked and is a laborious job to get the pipe line cleaned.
  3. The Calorific value of Producer Gas was low.
  4. No consistency in Gas quality and quantity.
  5. Frequent interruptions in the process due to chocking and cleaning of pipe line.
  6. Because of shallow bed it can perform only with high grade of coal.
  7. Single off-take from one side, will cause preferential flow of air-steam mixture resulting in non-uniform gasification reaction.
  8. Operational hazards due to heavy clinkering and jamming of the fire-bed.
  9. Low Thermal Efficiency.
  10. Limited use in industries due to low flame-temperature.
  11. Gasifiers were not pollution-free.

Due to above disadvantages, the source of energy in industries gradually changed from Producer Gas to Petro-gas, Fuel Oils which was available at low cost, had abundance of supply with low investment cost and Electricity so long as these were comfortably cheaper. But due to Global Energy crisis and price-hike of all kinds of Petro fuels, industries have tried to switch over to cheaper fuel. As coal is abundantly found in our country, industries should resort to Gaseous fuel based on coal.ഊIndia Industrial Enterprises Pvt. Ltd.

Schematics & Graphical Representations

Auto Safety Features DuringB.S.T.Contriol AreaB.S.T.Contriol-AreaBlast Air Flow ControlBlast Air Flow TrendControl & InstrumentationDrum Level Control AreaGas Outlet AreaPressure TrendsProcess ViewProducer Gas CompositionReactor Zone TemperaturesTemperature TrendsVapour Drum Level Trend

Auto Safety Features - animated schematic

New Generation Producer Gas Plant as developed and Patented (Patent No. 202603) by IIEPL.


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Objective of the New Generation Producer Gas Plant

The objective of the new technology was to produce a clean and consistent quality Producer Gas of higher Calorific Value from any grade of Indian Coal of A to F grade. With this objective in view, a deep coal — bed has been introduced above the insignificant product gas space and minimal distillation zone of the single stage gas-producer. The product gas has been diverted fully through this extended coal bed to come out from the top of the extended shaft at a temperature much below cracking temperature of Tar and the tar remains always at vapour phase.

The Basic Design Features of New Generation Producer Gas Plant with their advantages

The above novel features of auto-enrichment of Gas with inbuilt distillation of coal in an Extended Shaft Gasifier have improved the kinetics of gasification, specific mass-flow of gas per unit empty cross-section of Gasifier, Gas make per MT of coal, Calorific Value and consistency of Gas quality to a great extent.

The Constructional Features of New Generation Producer Gas Plant

The prime parts of a 100% Top Off-Take Producer Gas Plant are:

Various Process-Steps and Reaction Zones in the Gasifier


Features of Plant

Economy in Coal Gasification

Thus cost in Producer Gas firing is even less than One — Third the cost of Furnace Oil firing.