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Fuel gas, produced by the reduction of coal and peat, was used for heating as early as 1840 in Europe and by 1884 had been adapted to fuel engines in England. Prior to 1940, gas generator units were a familiar, but not extensively utilized, technology. However, petroleum shortages during World War II led to widespread gas generator applications in the transportation industries of Western Europe. (Charcoal burning taxis, a related application, were still common in Korea as late as 1970.) The United States, never faced with such prolonged or severe oil shortages, has lagged far behind Europe and the Orient in familiarity with and application of this technology. However, a catastrophic event could disrupt the supply of petroleum in this country so severely that this technology might be critical in meeting the energy needs of some essential economic activities, such as the production and distribution of food.
In occupied Denmark during World War II, 95% of all mobile farm machinery, tractors, trucks, stationary engines, and fishing and ferry boats were powered by wood gas generator units. Even in neutral Sweden, 40% of all motor traffic operated on gas derived from wood or charcoal. All over Europe, Asia, and Australia, millions of gas generators were in operation between 1940f and 1946. Because of the wood gasifier's health risks from toxic fumes, most of such units were abandoned when it again became available in 1945. Except for the technology of producing alternate fuels, such as methane or alcohol, the only solution for operating existing internal combustion engines, when oil and petroleum products are not available, has been these simple, inexpensive gasifiers units.
This report attempts to preserve the knowledge about wood gasification that was put into practical use during World War II. In this report, detailed step-by-step procedures are presented for constructing a simplified version of the WWII wood gas generator; this simple, stratified, downdraft gasifier unit (shown schematically in Fig. S-1) can be constructed from materials which would be widely available in the United States in a prolonged petroleum crisis. For example, the body of the unit consists of a galvanized metal garbage can atop a small metal drum; common plumbing fittings are used throughout; and a large, stainless steel mixing bowl is used for the grate. A prototype gasifier unit was fabricated from these instructions (see Fig. S-2); this unit was then mounted onto the front of a farm tractor and successfully field tested, using wood chips as the only fuel (see Fig. S-3). Photographic documentation of the actual assembly of the unit, as well as its operational field test, is included in the body of this report.
The use wood gas generators need not be limited to transportation
applications. Stationary engines can also be fueled by wood gasifiers to
run electric generators, pumps, and industrial equipment. In fact, the use
of wood gas as a fuel is not even restricted to gasoline engines; if a
small amount of diesel fuel is used for ignition, a properly adjusted
diesel engine can be operated primarily on wood gas introduced through the
S.1 Principles of solid fuel gasificationAll internal
combustion engines actually run on vapor, not liquid. The liquid fuels
used by gasoline engines are vaporized before they enter the combustion
chamber above the pistons. In diesel engines, the fuel is sprayed into the
combustion chamber as fine droplets which burn as they vaporize. The
purpose of a gasifier, then, is to transform solid fuels into gaseous ones
and to keep the gas free of harmful constituents. A gas generator unit is
simultaneously an energy converter and a filter. In these twin tasks lie
its advantages and its difficulties.
In a sense, gasification is a form of incomplete combustion-heat from the burning solid fuel creates gases which are unable to burn completely because of the insufficient amounts of oxygen from the available supply of air. Thee same chemical laws which govern combustion processes also apply to gasification. There are many solid biomass fuels suitable for gasification - from wood and paper to peat, lignite, and coal, including coke derived from coal. All of these solid fuels are composed primarily of carbon with varying amounts of hydrogen, oxygen, and impurities, such as sulfur, ash, and moisture. Thus, the aim of gasification is the almost complete transformation of these constituents into gaseous form so that only the ashes and inert materials remain. In creating wood gas for fueling internal combustion engines, it is important that the gas not only be properly produced, but also preserved and not consumed until it is introduced into the engine where it may be appropriately burned.
Gasification is a physiochemical process in which chemical transformations occur along with the conversion of energy. The chemical reactions and thermochemical conversions which occur inside a wood gas generator are too long and too complicated to be covered here; however, such knowledge is not necessary for constructing and operating a wood gasifier. By weight, gas (wood gas) produced in a gasifier unit contains approximately 20% hydrogen (H2), 20% carbon monoxide (CO), and small amounts of methane, all of which are combustible, plus 50 to 60% nitrogen (N2). The nitrogen is not combustible; however, it does occupy volume and dilutes the wood gas as it enters and burns in an engine. As the wood gas burns, the products of combustion are carbon dioxide (CO2) and water vapor (H20).
One of the by-products of wood gasification is carbon monoxide, a
poisonous gas. The toxic hazards associated with breathing this gas should
be avoided during refueling operations or prolonged idling, particularly
in inadequately ventilated areas. Except for the obvious fire hazard
resulting from the combustion processes inside the unit, carbon monoxide
poisoning is the major potential hazard during normal operation of these
simplified gasifier units.
S.2. THE STRATIFIED DOWNDRAFT GASIFIER Until the early 1980s,
wood gasifiers all over the world (including the World War II designs)
operated on the principle that both the fuel hopper and the combustion
unit be absolutely airtight; the hopper was sealed with a top or lid which
had to be opened every time wood was added. Smoke and gas vented into the
atmosphere while wood was being loaded; the operator had to be careful not
to breathe the unpleasant smoke and toxic fumes.
Over the last few years, a new gasifier design has been developed through cooperative efforts among researchers at the Solar Energy Research Institute in Colorado, the University of California in Davis, the Open University in London, the Buck Rogers Company in Kansas, and the Biomass Energy Foundation, Inc., in Florida. This simplified design employs a balanced, negative-pressure concept in which the old type of sealed fuel hopper is no longer necessary. A closure is only used to preserve the fuel when the engine is stopped. This new technology has several popular names, including "stratified, downdraft gasification" and "open top gasification." Several years of laboratory and field testing have indicated that such simple, inexpensive gasifiers can be built from existing hardware and will perform very well as emergency units.
A schematic diagram of the stratified, downdraft gasifier is shown in Fig. S-l. During operation of this gasifier, air passes uniformly downward through four zones, hence the name stratified:
The stratified, downdraft design has a number of advantages over the World War II gasifier designs. The open top permits fuel to be fed more easily and allows easy access. The cylindrical shape is easy to fabricate and permits continuous flow of fuel. No special fuel shape or pretreatment is necessary; any blocky fuel can be used.
The foremost question about the operation of the stratified, downdraft gasifier concerns char and ash removal. As the charcoal reacts with the combustion gases, it eventually reaches a very low density and breaks up into a dust containing all of the ash as well as a percentage of the original carbon. This dust may be partially carried away by the gas and might eventually begin to plug the gasifier. Hence, it must be removed by shaking or agitation. When the stratified gasifier unit is used to power vehicles, it is automatically shaken by the vehicle's motion.
An important issue in the design of the stratified, downdraft gasifier is the prevention of fuel bridging and channeling. High grade biomass fuels, such as wood blocks or chips, will flow down through the gasifier because of gravity and downdraft air flow. However, other fuels (such as shredded chips, sawdust, and bark) can form a bridge, which will obstruct continuous flow and cause very high temperatures. Bridging can be prevented by stirring, shaking, or by agitating the grate or by having it agitated by the vehicle's movement. For prolonged idling, a hand-operated shaker has been included in the design in this report.
A prototype unit of the stratified, downdraft gasifier design (se Figs. S-2 and S-3) has been fabricated according to the instructions in this report; however, it has not been widely tested at this time. The reader is urged to use his ingenuity and initiative in the construction of his own wood gas generator. As long as the principle of airtightness in the combustion regions, in the connecting piping, and in the filter units is followed, the form, shape, and method of assembly is not important.
The wood gasifier design presented in this report has as its origin the proven technology used in World War II during actual shortages of gasoline and diesel fuel. It should be acknowledged that there are alternate technologies (such as methane production or use of alcohol fuels) for keeping internal combustion engines in operation during a prolonged petroleum crisis; the wood gasifier unit described in this report represents only one solution to the problem.
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