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COMMISSIONING OF A PILOT SCALE FLUIDISED BED COMBUSTOR
MOHD. RUSWADI BIN JUSOH
UNIVERSITI TEKNOLOGI MALAYSIA
BAHAGIAN A – Pengesahan Kerjasama*
Adalah disahkan bahawa projek penyelidikan tesis ini telah dilaksanakan melalui
kerjasama antara _______________________ dengan _______________________
Disahkan oleh:
Tandatangan : Tarikh :
Nama :
Jawatan :
(Cop rasmi)
* Jika penyediaan tesis/projek melibatkan kerjasama.
BAHAGIAN B – Untuk Kegunaan Pejabat Sekolah Pengajian Siswazah
Tesis ini telah diperiksa dan diakui oleh:
Nama dan Alamat Pemeriksa Luar : _____________________________________
_____________________________________
_____________________________________
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Nama dan Alamat Pemeriksa Dalam : _____________________________________
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Nama Penyelia Lain (jika ada) : _____________________________________
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Disahkan oleh Timbalan Pendaftar di SPS:
Tandatangan : Tarikh :
Nama :
COMMISSIONING OF A PILOT SCALE FLUIDISED BED COMBUSTOR
MOHD. RUSWADI BIN JUSOH
A dissertation submitted in partial fulfillment of the
Requirements for the award of the degree of
Master of Engineering (Environmental)
Faculty of Chemical and Natural Resources Engineering
Universiti Teknologi Malaysia
OCTOBER 2008
iv
ACKNOWLEDGEMENT
I would like to express my sincere gratitude to my supervisor, Associate
Professor Dr. Mohd. Rozainee bin Taib for his dedication, support and guidance
throughout the whole period of this study work. His knowledge and experience in
the field of fluidised bed combustor system has enlightened me and inspired me in
the area of my study. Without his guidance and constructive criticism, this study
would not have been gone that smoothly. I also appreciate the freedom that he had
given to me in finishing my study in my own space.
v
ABSTRACT
The main purpose of this study is to perform a test and commissioning on a
newly fabricated pilot scale fluidised bed combustor for the production of ash from
rice husk. The combustor with the height of 6.0 mH and diameter of 0.5 mD has been
designed and installed at the Faculty of Chemical and Natural Resources, Universiti
Teknologi Malaysia. The scope of this study includes installation of the centrifugal
exhaust fan, modification of the combustor feeding system, observation on the
combustion temperature stability, oil palm shell usage as an igniter for the bed
combustor start-up and flue gas measurement from the firing of rice husk in the pilot
scale fluidised bed combustor. Under this study, a fluidising velocity of 4, 5, 6 and 7
Umf were applied for the combustion temperature stability observation on the
fluidised bed combustor. The oil palm shell obtained from the Kulai Palm Oil Mills
of Federal Land Development Authority (FELDA) Johor, were used as an igniter to
pre-heat the bed combustor in order to start-up the combustion process in a safe
manner during the experimental works. In addition, an installation of the centrifugal
exhaust fan and a modification on the feeding system was performed as a trouble-
shooting measured during the study. The flue gas from the combustion of rice husk
was analysed using the MRU Gas Analyser which showed that the gas generated
consists of O2, CO2, CO, NOx and SO2 at the concentration of 7.7%, 11.2%, 0.5%,
189 ppm and 80 ppm, respectively. The newly fabricated pilot scale fluidised bed
combustor was successfully commissioned with the production of ash from the firing
of rice husk in the unit.
vi
ABSTRAK
Matlamat utama dalam kajian ini adalah untuk menjalankan ujian keupayaan
terhadap loji pandu pembakar lapisan terbendalir untuk menghasilkan abu daripada
sekam padi. Loji pandu pembakar lapisan terbendalir yang mempunyai ketinggian
6.0 meter dengan saiz diameter 0.5 meter telah berjaya direkabentuk di Fakulti
Kejuruteraan Kimia dan Kejuruteraan Sumber Asli, Universiti Teknologi Malaysia.
Skop kajian ini termasuklah pemasangan kipas ekzos terhadap loji pandu, modifikasi
terhadap sistem suapan bahan bakar, ujian kestabilan suhu pembakaran loji pandu,
penggunaan isirung kelapa sawit sebagai bahan pemula untuk pemanasan bahan
lapisan terbendalir dan analisis terhadap gas yang terhasil daripada pembakaran
sekam padi di dalam loji pandu pembakar lapisan terbendalir. Melalui kajian ini,
halaju terbendalir terdiri daripada 4, 5, 6 dan 7 Umf diaplikasi dalam proses
pembakaran untuk menguji kestabilan suhu pembakaran loji pandu tersebut. Bagi
memastikan keselamatan sepanjang proses ujikaji, isirung kelapa sawit yang
diperolehi daripada Felda Taib Andak, Kulai digunakan sebagai bahan pemula untuk
proses pemanasan bahan terbendalir di dalam loji pandu. Selain daripada itu,
penambahan kipas ekzos terhadap loji pandu dan modifikasi terhadap sistem suapan
bahan bakar dilakukan untuk mengatasi masalah yang dihadapi semasa proses ujian
keupayaan dijalankan. Produk gas daripada pembakaran sekam padi di analisa
menggunakan penganalisa Gas MRU, ujian analisis terhadap gas O2, CO2, CO, NOx
dan SO2 yang terhasil masing-masing adalah sebanyak 7.6%, 11.2%, 0.5%, 189 ppm
and 80 ppm. Ujian keupayaan telah berjaya dilakukan ke atas loji pandu pembakar
lapisan terbendalir dengan penghasilan abu daripada pembakaran sekam padi melalui
unit tersebut.
vii
TABLE OF CONTENTS
CHAPTER TITLE PAGE
DECLARATION ii
DEDICATION iii
ACKNOWLEDGEMENT iv
ABSTRACT v
ABSTRAK vi
TABLE OF CONTENTS vii
LIST OF TABLES xi
LIST OF FIGURES xiii
LIST OF ABBREVIATIONS xvii
LIST OF APPENDICES xix
1 INTRODUCTION
1.1. Introduction 1
1.2. Problem Statements 3
1.3. Objectives of Study 4
1.4. Scopes of Study 5
1.5. Significance of Study 6
viii
2 LITERATURE REVIEW
2.1. Introduction 7
2.2. Paddy Milling Operation 8
2.2.1. Rice Husk Generation 10
2.3. Thermal Treatment of Rice Husk in
Fluidised Bed Combustor 11
2.4. Effect of Fluidising Parameters on the
Combustion Efficiency of Rice Husk
in Fluidised Bed Combustor 13
2.4.1. Fluidising Velocity (Umf number) 14
2.4.2. Sand Size 15
2.4.3. Static Bed Height 18
2.5. Effect of Fluidising Parameters on the
Combustion Efficiency of Rice Husk
in Fluidised Bed Combustor 20
2.5.1. Time 21
2.5.2. Temperature 22
2.5.2.1. Primary Stage 23
2.5.2.2. Secondary Stage 23
2.5.2.3. Tertiary Stage 23
2.5.3. Air Supply 24
2.5.3.1. Primary Air 25
2.5.3.2. Secondary Air 26
2.5.3.3. Pneumatic Air 27
2.5.4. Moisture Content in Rice Husk 27
2.6. Effect of Fluidising Parameters on the
Combustion Efficiency of Rice Husk
in Fluidised Bed Combustor 29
2.6.1. Freeboard Height 29
2.6.2. Feeding Design and Position of
Feed Entry of the Fluidised bed
Combustor 31
2.6.2.1. Effect on Ash Quality
(Carbon Burnout) 32
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3 METHODOLOGY
3.1. Introduction 34
3.2. Study Materials 34
3.2.1. Rice Husk 34
3.2.2. Oil Palm Shell 35
3.2.3. Silica Sand 36
3.3. Combustor System Equipments 37
3.3.1. Cyclone 37
3.3.2. Air Blower 37
3.3.3. Temperature Measuring System 38
3.3.4. Feeding System 38
3.3.5. Gas Analyser 38
3.3.5.1. Flue Gas Sampling
and Analysis 39
3.3.5.2. Measuring Principle 39
3.3.5.3. Technical
Specifications and
Measuring Ranges 40
3.4. Operating Parameters 44
3.4.1. Combustion Theoretical Air
Requirement 44
3.4.2. Combustion Air Flow Rate 46
3.4.3. Primary to Secondary Air Ratio 47
3.4.4. Bed Pre-Heating and Combustor
Start-up 48
4 RESULTS AND DISCUSSIONS
4.1. Introduction 51
4.2. Installation of the Centrifugal Exhaust Fan 52
4.3. Modification of Secondary Hopper on the
Combustor Feeding System 53
4.4. Bed Pre-heating and Combustor Start-up by
Using Oil Palm Shells 57
x
4.5. Combustion Temperature Stability 60
4.5.1. Rice Husk Combustion at 4, 5 and 6 Umf 60
4.5.2. Rice Husk Combustion at 7 Umf 62
4.5.3. Ash Production 63
4.6. Flue Gas Measurement 67
5. CONCLUSION AND RECOMMENDATIONS
5.1. Conclusion 72
5.2. Recommendations for Future Study 73
5.2.1. Dry Air Supply for Bed Pre-heating and
Combustor Start-Up 73
5.2.2. Removal of Oil Palm Shell Ash
Obtained from Bed Pre-heating and
Combustor Start-Up 74
5.2.3. Structure Analysis of Ash Samples 74
REFERENCES 75
APPENDICES 83
xi
LIST OF TABLES
TABLE NO. TITLE PAGE
Table 2.1: Description of paddy milling process 8
Table 2.2: Properties of sewage sludge and rice husk
(wt% dry basis) 15
Table 2.3: Sand size and corresponding fluidisation
velocity for combustion rice husk in fluidised bed 16
Table 2.4: Minimum fluidising velocity of sand
of various size ranges 18
Table 2.5: Static bed height used for the combustion
of rice husk 19
Table 2.6: Optimum air factor reported in literature for
combustion of rice husk in fluidised bed 24
Table 2.7: Different rice husk feeding arrangements 32
Table 3.1: Chemical properties of rice husk 35
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Table 3.2: Chemical properties of oil palm shell 36
Table 3.3: Physical properties of silica sand 36
Table 3.4: General specification of SWG 300-1 gas analyser 41
Table 3.5: Measuring ranges and accuracy as given
by the manufacturer 41
Table 3.6: Fluidising velocity and air flow rate for various
fluidising numbers in cold run (25oC) 46
Table 3.7: Fluidising velocity and air flow rate for various
fluidising numbers in hot run (800oC) 47
Table 3.8: Primary to secondary air ratio for varies
fluidising numbers 48
Table 4.1: Feed rate input for a different fluidising numbers 54
Table 4.2: Feeding rate calibration 55
Table E.1: Fluidising velocity and air flow rate for various
fluidising numbers at room temperature (25oC) 95
Table E.2: Fluidising velocity and air flow rate for various
fluidising numbers at hot run (800oC) 95
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LIST OF FIGURES
FIGURE NO. TITLE PAGE
Figure 2.1: Process flow diagram of paddy milling operation 9
Figure 2.2: Effect of secondary airflow on the temperature
distribution in the firebrick-insulated fluidised
bed combustor during the combustion of rice husk
(Chen et al., 1998) 26
Figure 2.3: Chart for transport disengaging height (TDH)
estimation of fine particle (Geldart A) beds (Zenz
and Weil, 1958) 30
Figure 3.1: Oxygen measurement principle 40
Figure 3.2: Schematic diagram of fluidised bed combustor 42
Figure 3.3: Schematic diagram of thermocouple position in the
pilot scale fluidised bed combustor 43
Figure 4.1: Installed centrifugal exhaust fan 53
Figure 4.2: Existing secondary hopper 55
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Figure 4.3: Schematic diagram of dead zone in existing
secondary hopper 56
Figure 4.4: Modified secondary hopper 56
Figure 4.5: Schematic diagram of modified secondary hopper 57
Figure 4.6: Real time of temperature profile for bed pre-heating 59
Figure 4.7: Real time temperature profile of rice husk
combustion at 4, 5 and 6 Umf 61
Figure 4.8: Real time temperature profile of rice husk
combustion at 7 Umf 63
Figure 4.9: Ash product from rice husk combustion
at 4 Umf 65
Figure 4.10: Ash product from rice husk combustion
at 5 Umf 66
Figure 4.11: Ash product from rice husk combustion
at 6 Umf 66
Figure 4.12: Ash product from rice husk combustion
at 7 Umf 67
Figure 4.13: Real time profile of CO, CO2 and O2 gas product
from rice husk combustion at 4, 5 and 6 Umf 69
Figure 4.14: Real time profile of NOx and SO2 gas product
from rice husk combustion at 4, 5 and 6 Umf 70
xv
Figure 4.15: Real time profile of O2 and CO2 and CO gas
product from rice rusk combustion at 7 Umf 70
Figure 4.16: Real time profile of NOx and SO2 gas
product from rice husk combustion at 7 Umf 71
Figure A.1: Real time temperature profiles for bed pre-heating
and combustor start-up 83
Figure A.2: Real time temperature profiles of rice husk
combustion at 4, 5 and 6 Umf 84
Figure A.3: Real time temperature profiles of rice husk
combustion at 7 Umf 84
Figure B.1: Ash product of rice husk combustion at 4 Umf 85
Figure B.2: Ash product of rice husk combustion at 5 Umf 86
Figure B.3: Ash product of rice husk combustion at 6 Umf 86
Figure B.4: Ash product of rice husk combustion at 7 Umf 87
Figure C.1: Real time profile for CO, CO2 and O2 gas product
of rice husk combustion at 4, 5 and 6 Umf 88
Figure C.2: Real time profile for NOx and SO2 gas product
of rice husk combustion at 4, 5 and 6 Umf 89
Figure C.3: Real time profile for CO, CO2 and O2 gas
product of rice husk combustion at 7 Umf 89
Figure C.4: Real time profile for NOx and SO2 gas
xvi
product of rice husk combustion at 7 Umf 90
Figure F.1: Cyclone 96
Figure F.2: Air blower 97
Figure F.3: PICO data acquision 97
Figure F.4: Feeding system 98
Figure F.5: MRU gas analyser 98
Figure G.1: Rice husk 99
Figure G.2: Oil palm shell 100
Figure G.3: Silica sand 100
xvii
LIST OF ABBREVIATIONS
ASEAN - Association of South-East Asian Nations
ASTM - American Society for Testing Materials
BET - Brunauer, Emmett and Teller Method
C - Carbon
CDM - Clean Development Mechanism
CH4 - Methane
CO - Carbon monoxide
CO2 - Carbon dioxide
CREDA - Chhattisgarh Renewable Energy Development Agency
Dc - Column Diameter
FELDA - Federal Land Development Authority
FBC - Fluidised Bed Combustor
FKKKSA - Fakulti Kejuruteraan Kimia dan Kejuruteraan Sumber Asli
GHG - Green House Gas
GJ - Giga Joule
GWh - Giga Watt per Hour
H - Hydrogen
HP - Horse Power
H2O - Water
H2S - Hydrogen Sulphide
HCI - Hydrochloric Acid
HHV - Higher Heating Value
ID - Internal Diameter
LHV - Lower Heating Value, (MJ/kg)
LOI - Loss on Ignition
xviii
LPG - Liquefied Petroleum Gas
LPM - Litre per Minute
mD - Meters (inner diameter)
mH - Meters (height)
mm - Millimeters
m/s - Meter per Second
MSW - Municipal Solid Waste
MW - Mega Watt
N - Nitrogen
NA - Not Available
ND - Not Detectable
NO2 - Nitrogen Dioxide
NSTP - New Straits Times Press
O2 - Oxygen
OH - Hydroxyl
RHA - Rice Husk Ash
RM - Ringgit Malaysia
RMS - Root Mean Square
S - Sulphur
SEM - Scanning Electron Microscopy
SiO2 - Silica Dioxide
SO2 - Sulphur Dioxide
TDH - Transport Disengaging Height, (m)
TGA - Thermogravimetric Analysis
Umf - Fluidising Velocity (number)
Umf/m - Fluidising Velocities of the Mixture
USA - United State of America
USD - United States Dollar (USD 1 = RM 3.80)
UTM - Universiti Teknologi Malaysia
XRD - X-Ray Diffraction
z - Static Height of Bed Materials
xix
LIST OF APPENDICES
APPENDIX TITLE PAGE
A Real time of temperature profile 83
B Ash product of rice husk combustion in the
pilot scale fluidised bed combustor 85
C Real time temperature profile of gas product
from combustion of rice husk 88
D Mass Balance to determine the amount
of stoichiometric air for combustion of rice husk 91
E Theoretical air requirement for rice husk combustion 93
F Picture of combustor system equipments 96
G Picture of materials used in study 99
CHAPTER 1
INTRODUCTION
1.1 Introduction
Rice covers 1% of the earth surface with approximately 600 million tonnes of
paddy produced per year with average 20% of the rice paddy is husk of 120 millions
tonnes. In majority of rice producing countries, most of the husk is either burnt or
dumped as a waste. According to the statistic from Padiberas Nasional Berhad
(BERNAS) in the year 2007, the potential energy generation in Malaysia from rice
husk is at 300 GWh per annum. This translates to, an estimated potential revenue
from electricity generation of RM44.7 million per annum.
The utilisation of rice husk for energy production added ‘value’ to rice husk,
which is otherwise deemed as a form of waste that have potential to create serious
environmental and health problems if not managed in a proper and effective manner.
Rice husk ash contains among the highest amount of biogenic silica still in its
amorphous form (in the excess of 95 wt% silica, SiO2) (James and Rao, 1986)
compared to other biomass materials, such as ash from sugarcane bagasse (57 – 73%
SiO2) (Natarajan et al., 1998a).
2
The quality of amorphous silica resulting from the thermal treatment of rice
husk is comparable with other expensive sources of silica. Furthermore, the
utilisation of rice husk producing value added material from waste agriculture
product as well as sodium silicate. The sodium silicate that could be produced in
much cheaper route using amorphous silica from rice husk ash compared to
conventional methods also has high market value. For example, the production of
one tonne of sodium silicate requires approximately 135 kg of amorphous silica as
raw material. Thus, one tonne of amorphous silica will produce an equivalent of 7.4
tonnes of sodium silicate, which in turn commands a price of RM 2,100 per tonne.
Further, the residue from the production of sodium silicate from rice husk ash is a
by-product which could be further processed into activated carbon or sold as it is as a
carbon source.
Production of rice is dominated by Asia, where rice is the only food crop that
can be grown during the rainy season in the waterlogged tropical areas. Most paddy
is produced by China (31%) followed by India (21%). Assuming a husk to paddy
ratio of 20% the total global husk production could be as high as 116,000,000 tonnes
per year. Globally, rice production is increasing from 1992 – 2002 with an increase
about 10%. Only China and Japan produced less rice in 2002 compared with 1992.
Yields are affected by several factors, including the agronomy of the crop. This is
influenced by the physical and cultural environment and scale under wish the rice is
grown. International co-ordination in technological advance of rice production is
providing alternatives to the limitation of cultures practices. Rice production is often
set by weather, monsoons and droughts, but the effect of this are increasingly being
limited by irrigation and water control systems.
In reality, it is estimated that only about 2% of the available rice husk is used
for energy production in Malaysia. Similarly, in other rice producing countries,
despite the huge potential, the utilisation of this abundant biomass is still very low.
However, in the last few years, the utilisation of rice husk as an energy source has
gained significant momentum. In reality, it is estimated that only about 2% of the
available rice husk is used for energy production in Malaysia. Similarly, in other rice
3
producing countries, despite the huge potential, the utilisation of this abundant
biomass is still very low. However, in the last few years, the utilisation of rice husk
as an energy source has gained significant momentum.
1.2 Problem Statements
A pilot scale fluidised bed combustor was successfully fabricated at Fakulti
Kejuruteraan Kimia dan Kejuruteraan Sumber Asli (FKKKSA), Universiti Teknologi
Malaysia. The combustor was of 0.5 mD (inner diameter) and 6.0 mH (height) which
was installed in February 2006. Commissioning of the pilot scale fluidised bed
combustor was carried out from March until July 2006.
The previous studies of rice husk combustion had been done in a lab scale of
80 mm inner diameter fluidised bed reactor (Ngo, 2002) to investigate the optimum
set of operating parameters such as temperature, sand size, fluidising velocity and
static bed height. A bed combustor pre-heating as a primary step in starting up the
combustor was pre-heated through premixed combustion of liquefied petroleum gas
(LPG) and air. An igniter such as kerosene or soaked tissue ball is dropped into the
bed. Then, the premixed LPG and air is passed through the bed with its flowrate
adjusted so as to enable the flame to remain in the bed. However, burning of the
premixed gas mixture in the bed region will emit a loud ‘popping’ noise due to the
eruption of bubbles in the bed during combustion.
In this study, the optimum set of operating parameters for production of
amorphous silica ash from rice husk (Ngo, 2002) could be applied to commission the
pilot scale fluidised bed combustor. Compared to the lab scale fluidised bed
combustor, the pilot scale fluidised bed combustor was of 0.5 mD (inner diameter)
and 6.0 mH (height) and the unit was facilitated with a gas analyser. During the
4
testing and commissioning activities, an evaluation, installation and modification was
carried out so as to ensure a good operation of the pilot scale fluidised bed
combustor.
1.3 Objectives of Study
The main objective of this study is to commission a newly fabricated pilot
scale fluidised bed combustor to produce ash from rice husk. The specific objectives
of this study were:
1. To investigate and overcome the leakage of smoke (hot flue gas) at
the combustor while the combustor is in operation.
2. To investigate the insufficient of the fuel feeding (rice husk) into the
combustor during the combustion process.
3. To evaluate a bed combustor pre-heating method for starting up the
pilot scale fluidised bed combustor by using an oil palm shell.
4. To investigate the combustion temperature stability of the fluidised
bed combustor by using a different of fluidising numbers (Umf).
5. To analyse a composition of flue gas generated from the rice husk
firing in the pilot scale fluidised bed combustor.
5
1.4 Scopes of Study
The study work focused on commissioning the newly fabricated pilot scale
fluidised bed combustor to produce ash from rice husk. The scopes of the study are
as below:
1. The installation of centrifugal exhaust fan on the top of the combustor
to provide the negative pressure on the chimney to prevent the escape
of the smoke (hot flue gas) at the combustor.
2. The modification of secondary hopper in the combustor feeding
system to avoid the insufficient of fuel feeding (rice husk) into the
combustor due to the dead zone in the existing secondary hopper
design.
3. The evaluation of combustor pre-heating method by using the oil
palm shell and the time to achieve a bed desire temperature (700oC)
will be observed.
4. The observation of combustion temperature stability will be carried
out for the rice husk firing in the combustor at fluidising numbers
applied from 4 to 7 Umf.
5. The measurement of flue gas will be carried out to determine a
composition of gases from the firing of rice husk in the combustor.
6
1.5 Significance of Study
This study will contribute on providing the effective technology (Fluidised
Bed Combustor) and solution for the utilisation of rice husk. It is in-line with the
Malaysia Budget 2008, which highlighted the continued emphasis to further
modernise and develop the agriculture sector industries. The study also explores the
potential utilisation of rice husk such as renewable energy source (heat and
electricity) and value added material (sodium silicate and activated carbon). The
most significant benefit that could be gained from such approach is that the zero or
most often negative investment that would have been expended to get rid of the
agricultural wastes could in fact be transformed into an income generating business
capable offering highly lucrative returns.
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