Wood Gasification Prototype (GP01-1000)
Air Flow Area Summary
Author: John Fedock P.E.
PowerItYourself.com
Jfedock@PowerItYourself.com
Revision
Date
2
07/25/13
1
07/14/13
0
07/01/13
Liability Disclaimer
This document has been written for informational purposes only. PowerItYourself P.L.
or any affiliates of PowerItYourself P.L. can not be held responsible for damage to property or
person caused by in appropriate utilization of information contain within said document.
In other words, I am building a PROTOTYPE design. I will be documenting the design,
construction, and operation of this wood gasifier modification. Do not utilize this information
unless you understand the complexity and inherent risk to this design.
Once I have finished my own testing, analysis, and the appropriate optimization. I will make
available a set of official manufacturing plans. You will be able to take this document to your
local fabrication shop. They will be able to give you a proper quote and build a high quality,
safe and efficient product.
Table of Contents
Statement of Purpose ............................................................................................................... 6
Station 1: Inlet Air Heat Exchanger #1 - Entrance.............................................................8
Station 2: Inlet Air Heat Exchanger #1 - Pass 1 ................................................................9
Station 3: Inlet Air Shell Turn 1........................................................................................10
Station 4: Inlet Air Shell Pass 2 ............................................................................................... 11
Station 5: Inlet Air Shell Floor Duct ......................................................................................... 12
Station 6: Inlet Air Shell 2 – Entrance ...................................................................................... 13
Station 7: Inlet Air Shell 2 – Pass 1 ......................................................................................... 14
Station 8: Inlet Air Shell #2 – Turn 1 ........................................................................................ 15
Station 9: Inlet Air Shell #2 – Pass 2 ....................................................................................... 16
Station 10: Inner Hearth (Gasification Zone) Entrance:........................................................... 17
Station 11: Exhaust Heat Exchanger Entrance: ...................................................................... 18
Station 12: Exhaust Heat Exchanger Pass 1: ......................................................................... 19
Station 13: Exhaust Heat Exchanger Turn 1: .......................................................................... 20
Station 14: Exhaust Heat Exchanger Pass 2: ......................................................................... 21
Station 15: Exhaust Plenum: ................................................................................................... 22
Station 16: Exhaust Flue: ........................................................................................................ 23
Appendix ................................................................................................................................. 24
Air Flow Stations (V.1) ....................................................................................................24
Station 1: Inlet Air Heat Exchanger #1 - Entrance...........................................................24
Station 2: Inlet Air Heat Exchanger #1 - Pass 1 ..............................................................25
Station 3: Inlet Air Shell Turn 1........................................................................................26
Station 4: Inlet Air Shell Pass 2 ............................................................................................... 27
Station 5: Inlet Air Shell Floor Transfer .................................................................................... 28
Station 6: Inlet Air Shell Floor Duct ......................................................................................... 29
Station 7: Inlet Air Shell 2 – Entrance ...................................................................................... 30
Station 7: Inlet Air Shell 2 – Pass 1 ......................................................................................... 31
Station 8: Inlet Air Shell #2 – Turn 1 ........................................................................................ 32
Station 9: Inlet Air Shell #2 – Pass 2 ....................................................................................... 33
Station 10: Inner Hearth (Gasification Zone) Entrance:........................................................... 34
Station 11: Exhaust Heat Exchanger Entrance: ...................................................................... 35
Station 12: Exhaust Heat Exchanger Pass 1: ......................................................................... 36
Station 13: Exhaust Heat Exchanger Turn 1: .......................................................................... 37
Station 14: Exhaust Heat Exchanger Pass 2: ......................................................................... 38
Station 15: Exhaust Plenum: ................................................................................................... 39
Station 16: Exhaust Flue: ........................................................................................................ 40
Air Flow Stations (V.0) ....................................................................................................41
STATION 1: Air Intake Ports ................................................................................. 41
STATION 2: Inlet Air Heater Pass 1 ....................................................................... 43
STATION 3: Inlet Air heater - Turn ......................................................................... 44
STATION 4: Inlet Air Heater Pass 2 ...................................................................... 45
STATION 5: Inner Hearth Air Entrance .................................................................. 46
STATION 6: Ash Pit Exit Ports ............................................................................... 47
STATION 7: Producer Gas Cooler – Pass 1 .......................................................... 48
STATION 8: Producer Gas Cooler – Turn 1 ........................................................... 49
STATION 9: Producer Gas Cooler – Pass 2 ......................................................... 50
STATION 10: Producer Gas Cooler – Turn 2 ......................................................... 51
STATION 11: Producer Gas Cooler – Pass 3 ........................................................ 53
STATION 12: Producer Gas Cooler – Turn 3 ......................................................... 54
STATION 13: Producer Gas Cooler – Pass 4 ....................................................... 55
STATION 14: Producer Gas Cooler - Exit .............................................................. 56
STATION 15: Exhaust Flue ................................................................................... 57
Illustration Index
Illustration 1: Flow Area Station Location Map (Rev. 2) ............................................................. 7
Illustration 2: Inlet Air Heat Exchanger #1 - Entrance ............................................................... 8
Illustration 3: Inlet Air Heat Exchanger #1 - Pass 1 ................................................................... 9
Illustration 4: Inlet Air Heat Exchanger #1 - Turn 1.................................................................. 10
Illustration 5: Inlet Air Heat Exchanger #1 - Pass 2 ................................................................. 11
Illustration 6: Inlet Air Heat Exchanger #1 - Floor Duct ........................................................... 12
Illustration 7: Inlet Air Heat Exchanger #2 – Entrance ............................................................. 13
Illustration 8: Inlet Air Heat Exchanger #2 – Pass 1 ................................................................ 14
Illustration 9: Inlet Air Shell 2 – Pass 2 .................................................................................... 16
Illustration 10: Inner Hearth (Gasification Zone) Entrance ...................................................... 17
Illustration 11: Exhaust Heat Exchanger Entrance .................................................................. 18
Illustration 12: Exhaust Heat Exchanger Pass 1 ..................................................................... 19
Illustration 13: Exhaust Heat Exchanger Turn 1 ...................................................................... 20
Illustration 14: Exhaust Heat Exchanger Pass 2 ..................................................................... 21
Illustration 15: Inlet Air Heat Exchanger #1 - Entrance ........................................................... 24
Illustration 16: Inlet Air Heat Exchanger #1 - Pass 1 ............................................................... 25
Illustration 17: Inlet Air Heat Exchanger #1 - Turn 1................................................................ 26
Illustration 18: Inlet Air Heat Exchanger #1 - Pass 2 ............................................................... 27
Illustration 19: Inlet Air Heat Exchanger #1 - Floor Transfer.................................................... 28
Illustration 20: Inlet Air Heat Exchanger - Floor Duct .............................................................. 29
Illustration 21: Inlet Air Heat Exchanger #2 – Entrance ........................................................... 30
Illustration 22: Inlet Air Heat Exchanger #2 – Pass 1 .............................................................. 31
Illustration 23: Inlet Air Shell 2 – Pass 2 .................................................................................. 33
Illustration 24: Inner Hearth (Gasification Zone) Entrance ...................................................... 34
Illustration 25: Exhaust Heat Exchanger Entrance .................................................................. 35
Illustration 26: Exhaust Heat Exchanger Pass 1 ..................................................................... 36
Illustration 27: Flow Area Station Location Map (Rev. 0) ......................................................... 41
Illustration 28: Air Intake Ports ................................................................................................ 42
Illustration 29: Inlet Air Heater Pass 1 ..................................................................................... 43
Illustration 30: Inlet Air Heater ................................................................................................. 44
Illustration 31: Inlet Air Heater - Pass 2 ................................................................................... 45
Illustration 32: Hearth Air Entrance ......................................................................................... 46
Illustration 33: Ash Pit Exit Ports ............................................................................................. 47
Illustration 34: Producer Gas Cooler - Pass 1 ......................................................................... 48
Illustration 35: Exhaust Cooler - Turn 1 ................................................................................... 49
Illustration 36: Exhaust Cooler - Pass 2 .................................................................................. 50
Illustration 37: 3D Producer Gas Cooler - Turn 2 .................................................................... 51
Illustration 38: Producer Gas Cooler - Turn 2.......................................................................... 52
Illustration 39: Exhaust Cooler - Pass 3 .................................................................................. 53
Illustration 40: Exhaust Cooler - Turn 3 ................................................................................... 54
Illustration 41: Exhaust Cooler - Pass 4 .................................................................................. 55
Illustration 42: Producer Gas Cooler Exit ................................................................................ 56
Illustration 43: Exhaust Flue.................................................................................................... 57
Statement of Purpose
This document will outline the cross sectional area (in²) for the air flow path through the gasifier.
This information is important because it will have an effect on the gasifier's operation efficiency and
gas quality. If the air is restricted at any point in the gasifier the overall performance will suffer.
At each air flow restriction or change in cross sectional area I am going call a “Station”. For example
station 1 would be the area of the inlet air entrance duct and the last station would be #16, the exhaust
flue.
The figure below will help you to understand where each station is located within the gasifier.
Illustration 1: Flow Area Station Location Map (Rev. 2)
Station 1: Inlet Air Heat Exchanger #1 - Entrance
Illustration 2: Inlet Air Heat Exchanger #1 - Entrance
Flow Area: 274 in^2
Station 2: Inlet Air Heat Exchanger #1 - Pass 1
Illustration 3: Inlet Air Heat Exchanger #1 - Pass 1
Flow Area: 91 in^2
Station 3: Inlet Air Shell Turn 1
Illustration 4: Inlet Air Heat Exchanger #1 - Turn 1
Flow Area: 116 in^2
Station 4: Inlet Air Shell Pass 2
Illustration 5:
Inlet Air Heat Exchanger #1 - Pass 2
Flow Area: 120 in^2
Station 5: Inlet Air Shell Floor Duct
Illustrat
ion 6: Inlet Air Heat Exchanger #1 - Floor Duct
Flow Area: 176 in^2
Station 6: Inlet Air Shell 2 – Entrance
Illustration 7: Inlet Air Heat Exchanger #2 – Entrance
Flow Area: 96 in^2
Station 7: Inlet Air Shell 2 – Pass 1
Illustra
tion 8: Inlet Air Heat Exchanger #2 – Pass 1
Flow Area: 181 in^2
Station 8: Inlet Air Shell #2 – Turn 1
H
Flow Area: 101 in^2
Station 9: Inlet Air Shell #2 – Pass 2
Illustration 9: Inlet Air Shell 2 – Pass 2
Flow Area: 95 in^2
Station 10: Inner Hearth (Gasification Zone) Entrance:
Illustration 10: Inner Hearth (Gasification Zone) Entrance
Flow Area: 103.5 in^2
Station 11: Exhaust Heat Exchanger Entrance:
Illustration 11: Exhaust Heat Exchanger Entrance
Flow Area: 141 in^2
Station 12: Exhaust Heat Exchanger Pass 1:
Illustration 12: Exhaust Heat Exchanger Pass 1
Flow Area: 284 in^2
Station 13: Exhaust Heat Exchanger Turn 1:
Illustration 13: Exhaust Heat Exchanger Turn 1
Flow Area: 300 in^2
Station 14: Exhaust Heat Exchanger Pass 2:
Illustration 14: Exhaust Heat Exchanger Pass 2
Flow Area: 296 in^2
Station 15: Exhaust Plenum:
Flow Area: 124 in^2
Station 16: Exhaust Flue:
Flow Area: 27.1 in^2
Appendix
Air Flow Stations (V.1)
Station 1: Inlet Air Heat Exchanger #1 - Entrance
Illustration 15: Inlet Air Heat Exchanger #1 - Entrance
Flow Area: 95 in^2
Station 2: Inlet Air Heat Exchanger #1 - Pass 1
Illustration 16: Inlet Air Heat Exchanger #1 - Pass 1
Flow Area: 190 in^2
Station 3: Inlet Air Shell Turn 1
Illustration 17: Inlet Air Heat Exchanger #1 - Turn 1
Flow Area: 132 in^2
Station 4: Inlet Air Shell Pass 2
Illustration 18: Inlet Air Heat Exchanger #1 - Pass 2
Flow Area: 235 in^2
Station 5: Inlet Air Shell Floor Transfer
Illustration 19: Inlet Air Heat Exchanger #1 - Floor Transfer
Flow Area: 121 in^2
Station 6: Inlet Air Shell Floor Duct
Illustration 20: Inlet Air Heat Exchanger - Floor Duct
Flow Area: 84 in^2
Station 7: Inlet Air Shell 2 – Entrance
Illustration 21: Inlet Air Heat Exchanger #2 – Entrance
Flow Area: 96 in^2
Station 7: Inlet Air Shell 2 – Pass 1
Illustration 22: Inlet Air Heat Exchanger #2 – Pass 1
Flow Area: 181 in^2
Station 8: Inlet Air Shell #2 – Turn 1
H
Flow Area: 101 in^2
Station 9: Inlet Air Shell #2 – Pass 2
Illustration 23: Inlet Air Shell 2 – Pass 2
Flow Area: 95 in^2
Station 10: Inner Hearth (Gasification Zone) Entrance:
Illustration 24: Inner Hearth (Gasification Zone) Entrance
Flow Area: 103.5 in^2
Station 11: Exhaust Heat Exchanger Entrance:
Illustration 25: Exhaust Heat Exchanger Entrance
Flow Area: 113 in^2
Station 12: Exhaust Heat Exchanger Pass 1:
Illustration 26: Exhaust Heat Exchanger Pass 1
Flow Area: 187.7 in^2
Station 13: Exhaust Heat Exchanger Turn 1:
Flow Area: 150.25 in^2
Station 14: Exhaust Heat Exchanger Pass 2:
Flow Area: 279 in^2
Station 15: Exhaust Plenum:
Flow Area: 124 in^2
Station 16: Exhaust Flue:
Flow Area: 27.1 in^2
Air Flow Stations (V.0)
Illustration 27: Flow Area Station Location Map (Rev. 0)
STATION 1: Air Intake Ports
Four (4) 3.3 inch diameter ports. Total flow area: 34.21 in²
Illustration 28: Air Intake Ports
STATION 2: Inlet Air Heater Pass 1
Flow area: 72.5 in²
Illustration 29: Inlet Air Heater Pass 1
STATION 3: Inlet Air heater - Turn
Flow Area: 109 in²
Illustration 30: Inlet Air Heater
STATION 4: Inlet Air Heater Pass 2
Flow Area: 95.3 in²
Illustration 31: Inlet Air Heater - Pass 2
STATION 5: Inner Hearth Air Entrance
Total Area 52.1 in²
Illustration 32: Hearth Air Entrance
STATION 6: Ash Pit Exit Ports
Four (4) 6 inch diameter ports
Ash Pit Exit flow area: 113in²
Illustration 33: Ash Pit Exit Ports
STATION 7: Producer Gas Cooler – Pass 1
Exhaust Pass Flow Area: 124.48in²
Illustration 34: Producer Gas Cooler - Pass 1
STATION 8: Producer Gas Cooler – Turn 1
Flow Area: 124.6in²
Illustration 35: Exhaust Cooler - Turn 1
STATION 9: Producer Gas Cooler – Pass 2
Air Flow Area: 152in²
Illustration 36: Exhaust Cooler - Pass 2
STATION 10: Producer Gas Cooler – Turn 2
Flow Area: 205in²
Illustration 37: 3D Producer Gas Cooler - Turn 2
Illustration 38: Producer Gas Cooler - Turn 2
STATION 11: Producer Gas Cooler – Pass 3
Flow Area: 169in²
Illustration 39: Exhaust Cooler - Pass 3
STATION 12: Producer Gas Cooler – Turn 3
Flow Area: 183 in²
Illustration 40: Exhaust Cooler - Turn 3
STATION 13: Producer Gas Cooler – Pass 4
Flow Area: 216.8 in²
Illustration 41: Exhaust Cooler - Pass 4
STATION 14: Producer Gas Cooler - Exit
Flow Area: 124in²
Illustration 42: Producer Gas Cooler Exit
STATION 15: Exhaust Flue
Flow Area: 26.4in²
Illustration 43: Exhaust Flue