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1 - Introducing The GEK Gasifier Systems - Rev5 PDF

The document introduces the Power Pallet gasification system from ALL Power Labs. [1] It provides specifications for the GEK gasifier systems available in 10kW, 20kW, and 100kW sizes. [2] It describes the different integration levels and components included in the Basic GEK, GEK TOTTI, and GEK Power Pallet models. [3] Key system components and the gasification process flow are illustrated.

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335 views7 pages

1 - Introducing The GEK Gasifier Systems - Rev5 PDF

The document introduces the Power Pallet gasification system from ALL Power Labs. [1] It provides specifications for the GEK gasifier systems available in 10kW, 20kW, and 100kW sizes. [2] It describes the different integration levels and components included in the Basic GEK, GEK TOTTI, and GEK Power Pallet models. [3] Key system components and the gasification process flow are illustrated.

Uploaded by

wawanUAI
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Introducing

the Power Pallet

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I. Overview and Specifications
ALL Power Labs offers downdraft gasifier systems in various sizes: 10kW, 20kW, and 100kW.
These kWe ratings reference the potential of electrical power capable in a gasifier/ICE/generator
system at the gasifier's maximum gas flow capacity. The GEK Power Pallet integrates an internal
combustion engine and a generator with automated controls with the ability to utilize the gas for other
purposes, while the GEK Gasifier comes as an assemble-yourself kit that provides stand-alone wood
gas for a variety of end uses. Below are the specifications of the systems provided by ALL Power Labs.

GEK Gasifier System Sizes provided by ALL Power Labs


10kW GEK 20kW GEK 100kW GEK
electrical capacity range (kW) 2 - 10 4 - 20 20 - 100
gas flow range (m^2/hr) 5 -27 11 - 53 53 - 267
gas heat flow at max (BTU/hr) 168,993 331,727 8,355,765
biomass consumption rate (kg/day) 160 - 320 320 - 640 640 - 3200
gasifier system footprint (excluding hopper) (ft) 2x4 2x4 4x7

The GEK Systems are offered at various integration stages as well as at different kit levels to
make the equipment accessible at various price points. The kit 'Levels' refer to the completeness of the
offered product. The levels are as follows:
 Level I: free CAD files available online
 Level III: Weld-It-Yourself kit (mild steel only)
 Level IV: Assemble-It-Yourself kit (stainless steel only)
 Level V: Completely Assembled and Integrated

GEK Gasifier Models, Levels and Features Offered


Model Sizes Levels Included Features
(kW) Available
Basic GEK 10, 20 I, III, IV Reactor, gas filter only. Gas drive system: ejector
GEK TOTTI 10, 20, III, IV Basic GEK with Pyrocoil and Drying Bucket. Gas drive system:
100 ejector
GEK Power 10, 20 V GEK TOTTI, PCU, logic and components for automation, engine
Pallet and generator. Gas drive system: blowers. Integrated on a 4x4
pallet. Available in 120V/208/240V AC, 60/50Hz, and in single,
split, or three phase configurations.

Biomass Requirements of the GEK Gasifier Systems

Most downdraft gasifier systems require specified feedstock characteristics and can be sensitive

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to feed stocks that lie outside of the required specifications for the given equipment. Across all of the
GEK Models above, ALL Power Labs has implemented designs in both the reactor and the bulk
handling systems that broaden the allowed feedstock characteristic requirements of typical systems of
its size. Below are the suggested ranges for given feedstock characteristics to be used in the GEK
systems.
Biomass Requirements
particle size (in) .5 - 1.5
moisture content (% by dry weight) <25
fixed to volatile ratio >0.25
ash content (%) >5
Please refer to the Feedstock Requirements and Preparation Guide for more information.

The GEK Systems are designed for raw biomass and organic-based feed stocks. Experimental
feed stocks lying outside of the suggested ranges may require modification of the equipment and
testing of the gas quality produced. For experimental and research, ALL Power Labs offers a Research
Experimenters Kit with test and control equipment valuable for gas testing or further development off
of the base systems. Contact sales@allpowerlabs.org for more information.

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II. Identifying the GEK System Components

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GEK System Components con't

1. Feedstock Hopper 26. Engine Radiator Coolant Port


2. Drying Bucket 27. Engine Alternator
3. Fuel Level Switch 28. 12V DC Car Battery (not included)
4. Pyrocoil Exhaust Port 29. Fuel Level Switch
5. Reactor 30. Pyrocoil and Exhaust Insulation Jacket
6. Auxiliary Port 31. Engine Exhaust
7. Gas Cowling 32. Engine Gas Valve
8. Manual Grate Shaker 33. Packed Bed Gas Filter Lid Access
9. Ash Port 34. Filter Condensate Drain Port
10. Dual Channel Manometer and Thermocouple 35. Automatic Flare Igniter
Port 36. Air Blower
11. Cyclone Condensate Jar 37. Air Filter
12. Air Inlet Check Valve 38. System Safety Relief Valve
13. Lighting Port 39. Generator and Electrical Connection Box
14. Cyclone 40. Engine Starter Motor
15. Gas Service Connection Port 41. Engine Condensate Trap
16. Biomass Feed Auger 42. Engine Oil Filter
17. Ejector Compressed Air Connection 43. Governor and Engine Throttle
18. Ejector Gas Drive 45. Oxygen Sensor
19. Swirl Burner 46. Automated Grate Shaker
20. Manual Air-Premix Valve 47. Feedstock Hopper View Port
21. Gas Shut-off Valve 48. Dual Gas Blower
22. Packed Bed Gas Filter 49. Pyrocoil Heat Exchanger
23. Hopper Barrel Puff Bung 50. Gas Line Access Port
24. Flare Stack 51. Process Control Unit (PCU) and Control Logic
25. Air Blower 52. Main Operation Panel

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III. Identifying the Power Pallet Control Panel and PCU Components

53. Hour Meter a. Power Input k. Low Range Pressure


54. Oxygen Sensor Air/Fuel b. FETs Sensors
Ratio Dial c. RS232 Communication Port l. High Range Pressure
55. LCD Display d. ATX Power Supply Sensors
56. 4 Input Buttons e. Input Buttons and Keypad Off-board m. Analog Inputs
57. System Main Power Connection n. ATmel MicroProcessor
58. Engine Key Switch f. Relay Board I/O Connectors o. CAN Bus
59. Dual Gas Blower g. Thermocouple Screw Terminal Communication Port
Adjustment Knob Connectors p. Reset Button
60. Air Blower Adjustment h. Thermocouple Standard Connectors q. Status LEDs
Knob i. LCD Display and Contrast Knob r. USB Communication Port
61. PCU USB Connection Port j. Micro SD card s. Servo Control Ports
62. Warning Alarm t. Timer

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IV. Description of the GEK Gasifier Process Flows
The GEK Process starts with the introduction of feedstock into the hopper. After the hopper, the
feedstock passes through an auger and enters the gasifier. The auger is controlled by a level switch
incorporated into the reactor lid. The feedstock fills the GEK reactor and stages needed for passes
through the stages of gasification: drying, pyrolysis, combustion, and reduction. The hot gas exits the
reactor and passes through a cyclone to separate char particulates. The GEK Gasifier systems are
designed to utilize the heat from the gas produced to dry the incoming feedstock through the Drying
Bucket. After the Drying Bucket, the gas passes through the gas filter and gas drive system. The GEK
Gasifier systems have two main valves to switch between one of two operational modes: Flare or
Engine Mode (or other gas utilization mode). For Engine Mode, the Pyrocoil heat exchanger, included
in the TOTTI design, increases the efficiency of the reaction by supporting the heat needed for the
pyrolysis zone by utilizing the waste heat from the exhaust of an engine or other process.

The GEK Gasifier Kits and the Power Pallet have different gas drive systems as shown in the
GEK Process Flow diagram above. For the GEK Kits, the gas enters the gas filter, and passes through
the ejector gas drive system. Here the air is then mixed for the flare.
For the Power Pallet, the gas by-passes the filter on start-up and the blower system provides gas and air
for the flare. After start-up, the flare is then shut off and the engine pulls gas through the gas filter.
The Basic GEK Kit does not include the Drying Bucket, Pyrocoil, or Auger shown in the diagram
above. The Basic GEK Kit has a simple lid on top of the reactor and is to be filled manually. The Basic
GEK Kits are offered as the most simple experimental development platform.

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