Chapter 2 Biomass
Chapter 2 Biomass
Pellet Mill
A pellet mill also known as pellet machine or pellet press is used for making pellets from different powdered
materials. It is usually composed of pellet die and rollers. In able to form the pellets, the feedstock are force
through the die holes by the rotating rollers or dies.
Boiler
In a thermal power plant, boilers are needed in able to produce a high pressure steam. A biomass-fired power
plant is a type of thermal power plant in which biomass fuels are fed and burned inside the combustion
chamber of a boiler in able to produce heat. The heat produced from the biomass fuels will be absorbed by
water; this will make the water evaporate and turn into steam.
1. Fire-tube boilers
In a fire-tube boiler, hot gases flow through tubes which are surrounded or enclosed by water.
The heat coming from the hot gases flowing through the tubes will make the water turn into
steam. Fire-tube boilers are usually used in small scale industries. One of the advantages of a
fire-tube boiler is its simple design. It is easier to maintain than a water-tube boilers which has a
complex design.
2. Water-tube boilers
In water-tube boilers, water flows through tubes that are surrounded by hot gases. Water-tube
boilers are the most widely used type of boiler today because of their fast steam generation
process. Aside from this, water-tube boilers have higher efficiency than fire-tube boilers.
The purpose of a steam turbine is to convert thermal energy coming from the steam into kinetic energy. The
high pressure steam will make the turbine rotate thus producing mechanical energy. The steam turbine is
connected into a generator that will convert the produced mechanical energy into electrical energy.
1. Impulse Turbine
In impulse turbines, high velocity superheated steam flowing out from fixed nozzles strikes the blades
or buckets; this will cause the turbine shaft to rotate. The high pressure and intermediate pressure
stages of a steam turbine are usually impulse turbines.
2. Reaction Turbine
In reaction turbines, the steam passes from fixed blades of the stator through the shaped rotor blades
nozzles causing a reaction and rotating the turbine shaft. The low pressure stage of a steam turbine
is usually a reaction type turbine.
In thermal power plants, generators convert mechanical energy into electrical energy. The generator shaft is
coupled to the turbine shaft where the mechanical energy is produced.
Steam condenser is an equipment used to condense the exhaust steam from a steam turbine by means of a
cooling water. The cooling water will absorb the heat from the exhaust steam; this will make the exhaust
steam condense.
The main function of a condenser is to convert gaseous form of exhaust steam into liquid form at a pressure
of below atmosphere. Usually, water is used as a cooling medium to convert steam into water. (Dr. Parvez,
2018)
The main function of a feed water pump is to supply pressurized feed water into the boiler. Usually, centrifugal
pumps are used as a feed water pump since it can transport a higher volume of fluid than a positive
displacement pump.
In a thermal power plant, cooling water pumps are used to transport water with low temperature coming from
the cooling towers into the condensers. Centrifugal pumps are used as a cooling water pumps due to its high
volume flow capacity.
Cooling Tower
Cooling tower is a device commonly used to cool condenser water in power and refrigerating plants. (Hipolito
Sta. Maria, 2001)
It is a type of equipment that transfers heat from hot water into the air. This will reduce the temperature of
the water. The hot water coming to the cooling tower usually came from the condenser; the water has a high
temperature since it absorbed the heat coming from the steam. After the cooling process, low temperature
water will be sent back into the condenser from the cooling tower.
Figure 2. Cooling Tower Diagram
(Source: Cooling Tower Products)
De-aerator
De-aerators are used to physically remove dissolved oxygen and carbon dioxide from the condensate/make-
up water. De-aerators reduce the oxygen content to levels low enough to avoid premature corrosion failures.
De-aerators operate on the principle of Henry’s law of partial pressures (the solubility of any gas dissolved in
liquid is directly proportional to the partial pressure of that gas above the liquid). Thus, the dissolved gases
in the feed water can be removed by spraying the water into a steam environment in which the partial pressure
of the gas is reduced. The de-aerated feed water eventually flows out of the de-aerator into a storage tank
while the oxygen and carbon dioxide are vented to the atmosphere, carried by a small amount of steam.
(Bradley N. Jackson, 2017)
Figure 2. De-aerator
(Source: Mechanical Engineering Site)
A type of filter that uses static electricity to extract soot and ash from exhaust fumes before they exit the
smokestacks. It is a common air pollution control device. It is typically used in power stations that burn fuels
to generate electricity. Smoke consists of tiny particles of soot that are suspended in hot and rising air. These
unburned particles of carbon are pulled out of the smoke by using static electricity in the precipitators, leaving
clean and hot air to escape the smokestacks. It is vital to remove this unreacted carbon from the smoke, as
it can damage buildings and harm human health - especially respiratory health. (Jordan Hanania et al., 2018)
A flue gas stack is a kind of structure through which combustion product gases or flue gas are exhausted into
the atmosphere. Flue gases are produced from the burning of fuels such as biomass fuels. Flue gases contain
carbon dioxide, water vapor, nitrogen, and oxygen. Pollutants such as carbon monoxide and nitrogen oxides
can also be contained by flue gases. In able to disperse exhaust pollutants over a greater area, flue gas
stacks have height of up to 400 meters or more.
Carbon 45.20%
Hydrogen 5.8%
Oxygen 47.60%
Nitrogen 1.02%
Sulfur 0.21%
Table 2. Ultimate Analysis of Rice Husk Briquettes
(Source: Andrew Ndudi Efomah & Agidi Gbabo, 2015)
𝑀𝐽 𝑀𝐽
Higher heating value of rice husk pellets: 15.129 𝑡𝑜 17.589
𝑘𝑔 𝑘𝑔
Note: Moisture content is inversely proportional to the calorific value
(Source: “Production and Characterization of Rice Husk Pellets” by Japhet, J.A., Tokan A., and
Muhammad, M.H., 2015)
Table 2. Rice Husk Pellet Specification
(Source: Season Tian, 2016)
Based on several studies, rice husk pellets have a higher calorific value than rice husk briquettes. Aside from
having a higher calorific value than rice husk briquettes, rice husk pellets are also easier to store. The
proponents have decided to use rice husk pellets as the main fuel of the biomass-fired power plant.
Therefore, the calorific value of rice husk pellets will be used in the computations.
𝑂
𝑸𝒉 = 33,820𝐶 + 144,212 (𝐻 − ) + 9,304𝑆
8
Where,
𝑘𝐽
𝑸𝒉 – Higher Heating Value in 𝑘𝑔 𝑜𝑓 𝑓𝑢𝑒𝑙
C – Carbon Content in %
H – Hydrogen Content in %
O – Oxygen Content in %
S – Sulfur Content in %
Theoretical Air-fuel Ratio
𝑨 𝑂
( ) = 11.5𝐶 + 34.5 (𝐻 − ) + 4.3𝑆
𝑭 𝒕 8
Or
𝑨 𝑄ℎ
( ) =
𝑭 𝒕 3117
Where,
𝑘𝐽
𝑸𝒉 – Higher Heating Value in 𝑘𝑔 𝑜𝑓 𝑓𝑢𝑒𝑙
𝑨 𝑘𝑔 𝑜𝑓 𝑎𝑖𝑟
(𝑭) - Theoretical air-fuel ratio in 𝑘𝑔 𝑜𝑓 𝑓𝑢𝑒𝑙
𝒕
C – Carbon Content in %
H – Hydrogen Content in %
O – Oxygen Content in %
S – Sulfur Content in %
𝑨 𝐴
( ) = ( ) (1 + 𝑒)
𝑭 𝒂 𝐹 𝑡
𝑨 𝑘𝑔 𝑜𝑓 𝑎𝑖𝑟
(𝑭) - Actual air-fuel ratio in 𝑘𝑔 𝑜𝑓 𝑓𝑢𝑒𝑙
𝒂
𝑨 𝑘𝑔 𝑜𝑓 𝑎𝑖𝑟
(𝑭) - Theoretical air-fuel ratio in 𝑘𝑔 𝑜𝑓 𝑓𝑢𝑒𝑙
𝒕
e – Excess air in %
𝑾𝒇𝒈 = 𝑊𝑎 + 𝑊𝑓
Where,
𝑊𝑎 – Weight of air
𝑊𝑓 – Weight of fuel
The Ideal Rankine Cycle is a theoretical and the simplest process of a steam power plant.
Heat Added
𝑘𝐽
𝑸𝒂 = ℎ3 − ℎ2 ;
𝑘𝑔
𝑸𝒂 = 𝑚(ℎ3 − ℎ2 )
Where,
𝑄𝑎 – Heat Added in kW
𝑘𝐽
ℎ3 – Enthalpy of Steam in 𝑘𝑔
𝑘𝐽
ℎ2 – Enthalpy of feed water in 𝑘𝑔
𝑘𝑔
m – Mass flow rate of steam in 𝑠
Heat Rejected
In a Rankine Cycle, heat rejection occurs in the condenser. Using energy balance:
𝑘𝐽
𝑸𝒓 = ℎ4 − ℎ1 ;
𝑘𝑔
𝑸𝒓 = 𝑚(ℎ4 − ℎ1 )
Where,
𝑄𝑟 – Heat Rejected in kW
𝑘𝐽
ℎ4 – Enthalpy of Exhaust Steam in 𝑘𝑔
𝑘𝐽
ℎ1 – Enthalpy of condensate water in 𝑘𝑔
𝑘𝑔
m – Mass flow rate of steam in 𝑠
Turbine Work
𝑘𝐽
𝑾𝒕 = ℎ3 − ℎ4 ;
𝑘𝑔
𝑾𝒕 = 𝑚(ℎ3 − ℎ4 )
Where,
𝑊𝑡 – Turbine Work in kW
𝑘𝐽
ℎ3 – Enthalpy of Steam in 𝑘𝑔
𝑘𝐽
ℎ4 – Enthalpy of Exhaust Steam in 𝑘𝑔
𝑘𝑔
m – Mass flow rate of steam in 𝑠
Pump Work
In a Rankine Cycle, pump work is necessary in able to transport the feed water into the boiler. Using energy
balance:
𝑘𝐽
𝑾𝒑 = ℎ2 − ℎ1 ;
𝑘𝑔
𝑾𝒑 = 𝑚(ℎ2 − ℎ1 )
Where,
𝑊𝑝 – Pump Work in kW
𝑘𝐽
ℎ2 – Enthalpy of feed water in 𝑘𝑔
𝑘𝐽
ℎ1 – Enthalpy of condensate water in 𝑘𝑔
𝑘𝑔
m – Mass flow rate of steam in 𝑠
𝑾𝒑 = 𝑚𝑉𝑓 (𝑃𝐵 − 𝑃𝐶 )
Where,
𝑊𝑝 – Pump Work in kW
𝑘𝑔
m – Mass flow rate of steam in 𝑠
𝑚3
𝑉𝑓 – Specific volume of condensate in 𝑘𝑔
𝑃𝐵 – Boiler pressure in kPa
𝑃𝐶 – Condenser pressure in kPa
𝑊𝑝
𝑾𝒂𝒑 =
η𝑝
Where,
𝛈𝒑 – Pump efficiency
𝑊𝑎𝑝 – Actual Pump Work
Net cycle work is the theoretical work produced in an ideal Rankine cycle.
𝑾𝒏𝒆𝒕 = 𝑊𝑡 − 𝑊𝑝 = 𝑄𝑎 − 𝑄𝑟
Thermal Efficiency
𝑊𝑛𝑒𝑡 𝑄𝑎 − 𝑄𝑟 𝑄𝑟
𝛈𝒕𝒉 = = =1−
𝑄𝑎 𝑄𝑎 𝑄𝑎
Where,
Boiler Efficiency
𝑇ℎ𝑒𝑟𝑚𝑎𝑙 𝐸𝑛𝑒𝑟𝑔𝑦
𝛈𝑩 =
𝐶ℎ𝑒𝑚𝑖𝑐𝑎𝑙 𝐸𝑛𝑒𝑟𝑔𝑦
Turbine Efficiency
𝑀𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝐸𝑛𝑒𝑟𝑔𝑦
𝛈𝑻 =
𝑇ℎ𝑒𝑟𝑚𝑎𝑙 𝐸𝑛𝑒𝑟𝑔𝑦
Generator Efficiency
𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑎𝑙 𝐸𝑛𝑒𝑟𝑔𝑦
𝛈𝑮 =
𝑀𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝐸𝑛𝑒𝑟𝑔𝑦
𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑎𝑙 𝐸𝑛𝑒𝑟𝑔𝑦
𝑶𝒗𝒆𝒓𝒂𝒍𝒍 𝑬𝒇𝒇𝒊𝒄𝒊𝒆𝒏𝒄𝒚 = (𝛈𝑩 )(𝛈𝑻 )(𝛈𝑮 ) =
𝐶ℎ𝑒𝑚𝑖𝑐𝑎𝑙 𝐸𝑛𝑒𝑟𝑔𝑦
(Source: Dutton, 2011)
𝑚𝑠 (ℎ4 − ℎ1 ) = 𝑚𝑤 𝐶∆𝑇
Where,
𝑘𝑔
𝑚𝑠 – Mass flow rate of steam in 𝑠
𝑘𝐽
ℎ4 – Enthalpy of Exhaust Steam in 𝑘𝑔
𝑘𝐽
ℎ1 – Enthalpy of condensate water in 𝑘𝑔
𝑘𝑔
𝑚𝑤 – Mass flow rate of cooling water in
𝑠
𝑘𝐽
𝐶 – Specific heat of water, 4.187 𝑘𝑔 °𝐾
∆𝑇 – Change in temperature, ˚K or ˚C
Cooling towers serve the vital role of cooling water for power plant heat exchange equipment. Sustaining
excellent system performance is important because a one-degree increase in water temperature can cause
a 2% increase in energy usage. Proper maintenance and a few upgrades could improve a cooling tower’s
efficiency, while also saving water in the process. (Abby L. Harvey, 2017)
𝑅𝑎𝑛𝑔𝑒
𝑪𝒐𝒐𝒍𝒊𝒏𝒈 𝑻𝒐𝒘𝒆𝒓 𝑬𝒇𝒇𝒊𝒄𝒊𝒆𝒏𝒄𝒚 =
𝑅𝑎𝑛𝑔𝑒 + 𝐴𝑝𝑝𝑟𝑜𝑎𝑐ℎ
Where,
𝑹𝒂𝒏𝒈𝒆 = 𝑇ℎ𝑜𝑡 𝑤𝑎𝑡𝑒𝑟 − 𝑇𝑐𝑜𝑙𝑑 𝑤𝑎𝑡𝑒𝑟
Height of Stack
𝐷𝑟𝑎𝑓𝑡 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒
𝑯𝒆𝒊𝒈𝒉𝒕 𝒐𝒇 𝑺𝒕𝒂𝒄𝒌 =
𝜌𝑎 − 𝜌𝑔
Where,
𝑘𝑔
𝐷𝑟𝑎𝑓𝑡 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = (𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 ℎ𝑒𝑎𝑑 𝑖𝑛 𝑚𝐻2 𝑂)(𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 𝑖𝑛 )
𝑚3
𝑘𝑔
𝜌𝑎 – Density of air in 𝑚3
𝑘𝑔
𝜌𝑔 – Density of flue gas in 𝑚3
Diameter of Stack
𝑸𝒈 = 𝐴𝑉
(𝜋)(𝐷2 )
𝑸𝒈 = ( ) (𝑉)
4
4𝑄𝑔
𝑫=√
(𝜋)(𝑉)
Where,
D – Diameter of Stack
𝑄𝑔 – Volume flow rate of flue gas
V – Velocity of flue gas
𝑳 = 𝐿𝐵 + 2𝑐
Where,
𝒂 = 𝑤 + 2𝑐
Where,
𝑾𝒇 = (3 𝑡𝑜 5)(𝑊𝑚 )
Where,
𝑊𝑓
𝑽𝒇 =
𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑡ℎ𝑒 𝑏𝑢𝑖𝑙𝑑𝑖𝑛𝑔 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙
𝑁(𝑊𝑚 + 𝑊𝑓 )
𝒃=
(𝑆𝑏 )(𝐿)
Where,
N – Factor of safety
𝑆𝑏 – Soil bearing capacity
2𝑉𝑓
𝒉=
(𝑎 + 𝑏)𝐿
Capital Cost
𝑃ℎ𝑝
𝑮𝒆𝒏𝒆𝒓𝒂𝒕𝒊𝒐𝒏 𝑹𝒂𝒕𝒆 = 4.8024
𝑘𝑊ℎ
8760 ℎ𝑟𝑠
𝑨𝑮𝑰 = (𝐺𝑒𝑛𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑅𝑎𝑡𝑒)(𝑃𝑜𝑤𝑒𝑟 𝐷𝑖𝑠𝑝𝑎𝑡𝑐ℎ𝑒𝑑; 𝑘𝑊) ( )
1 𝑦𝑒𝑎𝑟
𝑷=𝐼−𝐸
𝑷
𝑹𝑶𝑰 = 𝐱 𝟏𝟎𝟎%
𝑪𝒂𝒑𝒊𝒕𝒂𝒍 𝑪𝒐𝒔𝒕
2.1.3 Equipment Specifications
DESIGN OPTION 1:
Steam Boiler
ZG-75/3.82T
Capacity 75 t/h
AT76C
Dimensions (L x W x H) 6.8m x 4m x 3m
Inlet Temperature 28 ˚C
Note: Copper or copper alloys like copper-nickel alloy is recommended by the proponents as the main
material for the condenser tubes due to its high resistance to corrosion, high thermal conductivity, and low
maintenance cost.
Outlet Temperature 28 ˚C
Range 14.8961 ˚C
Approach 4 ˚C
Note: According to PAGASA, the average air temperature in Isulan, Sultan Kudarat is 27 ˚C and the average
humidity in the Philippines is 78%; using these data, the computed average wet bulb temperature in Isulan
is 23.97 ˚C or approximately 24 ˚C.
DESIGN OPTION 2:
Boiler
ZZ-75/5.3-M
Capacity 75 t/h
Fuel Biomass
SST-150
Power output Up to 20 MW
Dimensions (L x W x H) 12m x 4m x 5m
Weight 55 Tons
KYSB
Capacity 𝑚3
3,975 ℎ𝑟
Circulating Water 𝑚3
3,975 ℎ𝑟
Outlet Temperature 28 ˚C
Range 10.1369 ˚C
Approach 4 ˚C
XGJ1050
Power 360 kW