1. Introduction
The increase in global energy demand, along with climate change threats and geopolitical instability that affect fossil fuel availability, have shifted energy demand toward renewable energy sources [
1,
2]. Compared to traditional fossil fuels, biomass is broadly available and produces a lower impact on the environment [
3]. The production of energy from biomass solves some fundamental problems affecting other forms of renewable energy, such as wind and solar energy, as complex storage and the ability to produce energy when needed [
4,
5]. Easy to store, biomass guarantees continuity of supply and availability of energy, and its negligible sulfur content along with highly volatile components of most types of lignocellulosic biomass increase the benefits of its use in gasification processes [
6,
7]. Gasification represents a promising technology for converting biomass into a fuel source [
8,
9,
10,
11]. Through a series of chemical reactions, gasification leads to the production of a synthetic gas, the so-called syngas [
12,
13,
14], which possesses a larger energy density than biomass and can be used in many applications, including fuel cell power generation, internal combustion engines (ICE) or gas turbines [
15,
16] After properly cleaned of ashes and tar (a complex mixture of condensable hydrocarbons), syngas is mostly composed of carbon monoxide (CO), carbon dioxide (CO
2), hydrogen (H
2) and methane (CH
4) besides nitrogen (N
2) in the case of air or enriched air as an oxidant carrier agent [
3,
17].
Fluidized bed gasification (FBG) is a widely commercialized technology for converting biomass into a fuel source. One key advantage of FBG is the ability to maintain a constant bed temperature using bubbling beds composed of a mixture of biomass and materials, such as olivine, K-feldspar, quartz sand or sepiolite. [
18], which act as thermal energy carriers and mixers [
19]. The selection of appropriate bed material gives benefit to the process in terms of heat transfer, mass transfer and fuel mixing so as to allow the reactor to maintain an isothermal behavior and high performance. Thus, by means of a thoughtful selection of suitable minerals, bed properties can be evaluated in order to optimize the gasification process and increase the syngas quality by facilitating biomass conversion and guaranteeing limited contents of undesirable products such as tar and alkali compounds. The optimal materials to employ are determined by chemical, mechanical and environmental considerations. However, too frequently, the mechanical and economic factors are prioritized above the chemical consequences that inevitably lead to affecting the quality of the syngas. Several research works have focused on the importance of the study of chemical reactions occurring in gasifiers with the aim of obtaining a syngas with the lowest concentration of pollutants [
15], while there is a lack of study about the interaction that occurs between the different bed materials and the selected biomass. Some authors found that tar decreased while H
2 production increased due to improved steam reforming and water–gas shift reactions in fluidized beds where olivine served as bed material [
20,
21]. Different materials were also tested, e.g., Soria-Verdugo et al. 2019 [
22] conducted research focused on studying the gasification process of a lignocellulosic biomass in a bubbling fluidized gasifier. Sepiolite, a lower particle density material, was tested, and a larger H
2 production together with a lower tar concentration were found. With regard to the reduction of metal emissions, many studies have proposed various strategies that involved the assessment of the bed and the materials that constitute it [
23,
24,
25].
In previous works [
26,
27], some of the most commonly used materials in the literature (i.e., olivine, K-feldspar, calcite and kaolinite [
28,
29]) were lab-scale-tested in order to establish which minerals were the most suitable for the bed constitution. Tests were conducted in TGA-DSC (thermogravimetric and differential scanning calorimetry analysis) that proved to be an excellent lab-scale approximation for the evaluation of syngas produced from a fluidized bed gasificator [
26], with a few milligrams of material combined with a few milligrams of arboreal or herbaceous biomass obtained from plant-assisted bioremediation (PABR) processes [
30], with the aim to determine which material of the bed provided better performance in terms of less heavy metal syngas contamination. It turned out that K-feldspar was the most versatile material, with optimal results with both arboreal and herbaceous PABR biomass, while olivine provided good results only with arboreal PABR biomass. This research work represents a step forward in the assessment of such an analysis: results previously obtained were used as a basis for operating on a real prototypal plant of fluidized bed gasification, in which the best-performing materials in a lab-scale test, olivine (O) and K-feldspar (K), have been compared using almond shells which, although not obtained from PABR processes, are an arboreal biomass widely available in large quantities. By means of a pilot scale FBG system, this research study aims to upgrade previous works with the purpose of providing a solid foundation for the selection of the best bed material in accordance with the type of biomass used to build an FBG plant, which yields a hydrogen-rich syngas with the fewest contaminants released by the biomass-bed interaction.
2. Materials and Methods
The gasification tests, the preliminary analysis as well as the instrumental measurements were all performed at LASER-B (Laboratory for Experimental Activities on Renewable Energy from Biomass) located at CREA-IT (Council for Agricultural Research and Economic—department of Engineering and Agri-food transformations) in Monterotondo (Italy).
2.1. Biomass and Bed Materials Characterization
Almond shells (not obtained from PABR) were subjected to chemical–physical analysis in order to determine moisture and ash content, lower heating value (LHV), higher heating value (HHV) and elemental composition in terms of C, H, N and S. Preliminarily, the biomass was ground with a RetschSM 100 knife mill and then dried with a Memmert UFP800 oven at 105 ± 2 °C for 24 h. The moisture content was determined in accordance with EN ISO 18134-1:(2015). The ash content was determined in accordance with EN ISO 18122:(2015): about one gram of biomass was placed in a muffle furnace (Lenton EF/11 8B) and first heated up to 250 °C for two hours with a 6.5 °C/min ramp and then up to 550 °C for one hour with a 10 °C/min ramp. HHV was determined in accordance with EN ISO 18125:(2009) using an Anton Paar 6400 isoperibolic calorimeter. Finally, LHV was obtained using the HHV and the hydrogen percentage.
The elemental analysis, allowing the determination of carbon, hydrogen, nitrogen and sulfur content, was measured in accordance with EN ISO 16848:(2015) using a Costech ECS 4010 CHNS-O elemental analyzer. About 5 mg of the sample was weighted into tin capsules and then placed into the reactor. The limit of quantification (LOQ) showed to be 0.05% w/w for each sample. The oxygen content was then determined by comparing dry samples (UNI EN ISO 16948:2015). All biomass characterization tests were conducted in duplicate.
Metal content was investigated both in biomass and in bed materials. Samples (≈ 500 mg) were mineralized in acid environment using a microwave digester (Start D, Milestone, Italy) in order to make the sample suitable for introduction into an inductively coupled plasma mass spectometer (ICP-MS) system (Agilent 7700). A solution for the acid composed of 6 mL of HNO3 (65% v/v) and 3 mL of H2O2 (30% v/v) was used for the acid attack and the sample solubilization. The instrument was calibrated using multi-element standards (Standard mix, concentration 10 ppm in metal, Ultrascientific) in an acidified aqueous solution (HNO3 2% v/v). The calibration line was developed with four standards ranging in concentration from 50 to 1000 ppb. Yttrium was employed as the internal standard via the instrument’s automated input mechanism.
2.2. FBG Plant and Syngas Sampling
The gasification experiments were performed at CREA-IT in the fluidized bed gasifier (1 kW
th) facility held by DIMA (Department of Mechanical and Aerospace Engineering—Sapienza University of Rome), previously adopted and described in recent studies [
31,
32]. The gasification plant used is shown in
Figure 1. Olivine and K-feldspar selected as bed materials were sieved to ensure a granulometry between 100 and 200 µm. For each test, 1 kg of bed material was used. The density of bed materials was 3.49 g/cm
3 for olivine and 2.77 g/cm
3 for K-feldspar. The system operated at constant (atmospheric) pressure, with a small overpressure in the fluidized bed of about 200 mbar (20 kPa). After being preheated in a wind box, air was sent into the FBG from the bottom side of the reactor with a mass flow rate adequate to generate a bubbling bed as well as to feed the gasifier with a sufficient quantity of oxygen required to support the gasification reactions (
Table 1) [
33]. In agreement with [
34], reactor temperature was set at 820 °C. A LabView
® application was used to control oxidant agent flow (air) by means of a mass-flow controller (Bronkhorst MFC 50 L/min). A Bronkhorst MFC calibrated for syngas flow rates ranging from 8 to 400 Nml/min was used to compute the syngas slipstream sent to the metals, tar and VOC sampling systems shown below.
The biomass was introduced into FBG through a screw fed by an electric motor and supplied by a tank. It was chosen to condition the system before the start of the sampling test to ensure a correct temperature distribution. In particular, tests were started about an hour after the achievement of the operating temperatures. The reaction time was about 1 h. The reaction was conducted for the time strictly necessary for the conditioning of the plant and the sampling phase. A pipe placed in the top region allows the produced syngas to be delivered to the cleaning section. On the contrary, the majority of char and ashes remain trapped in the reactor and mix with the bed material. The syngas purification section consists of a cyclone that removes the biggest char and ash fractions carried by the gas flow and a ceramic filter that heats the gas to 400 °C to promote thermal degradation of heavy compounds while preventing tar deposits. Finally, syngas passes into the final impingers system for fugitive ashes, tar and metals. A mass flow controller has been placed downstream from the impingers system, which allows recording the flow of syngas that has passed through the sampling system. The ashes present on the bottom of the reactor (bottom ashes) and those separated by the cyclone (flying ashes) were also collected and analyzed to determine the metal content. Syngas was collected using Tedlar® bags after the ceramic filter and subsequently characterized with a 3000 Micro GC Inficon gas analyzer in order to obtain the syngas composition on a dry basis. Bottom ashes are the heaviest fraction and are collected and mixed with char in the lower part of the gasifier. Hence, the presence and potential interaction of such components with the bed materials must be considered during analysis. Flying ashes are easily transported by the generated syngas and captured by the cyclone. Fugitive ashes, lastly, are caught by the trapping system consisting of the three impingers placed downstream of the ceramic filter.
It is possible to analyze the bottom ash deposit by comparing the metal contents of the reactor after the conclusion of the gasification with the material employed as a bed and, equally important, the possible release of volatile metals from the bed materials and the successive transport in the syngas.
2.3. Metals and Tar Sampling and Analysis
The produced syngas was sampled in order to evaluate the metals and tar presence. A system of three impingers (250 mL, DadoLab) was set up in line and immersed in a thermostatic bath at sub-ambient temperature (5 ± 1 °C, DadoLab Chiller SC5). Syngas was bubbled inside the impingers each filled with 100 mL of a suitable solution for sampling the analytes. A solution of HNO3 and H2O2 in milli-Q water was used for the metals’ sampling. This solution has a content of HNO3 ≈ 3.3% v/v and H2O2 ≈ 1.5% v/v, according to UNI EN 14385. Tar was sampled by bubbling the syngas in the same way in a ≈ 50% isopropanol solution. The third impinger, in both cases, is defined as backup and is used to check that the sampling was quantitative. A correct sampling requires that the concentration of the analytes in the third impinger does not exceed 5% compared to the sum of the same in the first two impingers. The impingers were placed at sub-ambient temperature in a thermal bath at 5 °C, to favor the trapping efficiency. The bubbled solutions were analyzed with the ICP-MS described above to determine the concentrations of the metal species, while the collected tar solutions were injected into a gas chromatograph coupled with a mass spectrometer (GC-MS) system (Agilent 7000). All experiments were carried out in duplicate.
2.4. VOCs Sampling and Analysis
Volatile organic compounds were also collected downstream of the gasifier. A sampling ATA (Air toxic analyzer, Markes Int.) was used in order to capture VOCs produced during the gasification process. Samplings were carried out by placing the adsorbent tubes in correspondence with the gasifier’s gas outlet. Active sampling of the syngas was carried out at a flow of 50 mL/min using an appropriate sampling pump. All tests were conducted in duplicate. A thermal desorber 100-XR (TD, Markes Int.) was used for the analysis, carried out with an Agilent 7000 GC-MS system. Tubes were desorbed according to the method described by Paris et al. [
35]. The GC-MS analysis was conducted according to the protocol outlined in
Table 2, in splitless. The acquisition of volatile organic compounds (VOCs) was executed utilizing the full-scan mode within the mass-to-charge ratio range of 35-450 utilizing an electron ionization (EI) source at a temperature of 250 °C [
35].
4. Conclusions
The research study investigated the behavior of two of the most used bed materials in the FBG process of almond shells, an agroforestry by-product. This work is the upgrading in prototype scale of a previous lab-scale study in which four bed materials were compared with arboreal and herbaceous biomass to determine if during gasification contaminants are released into the syngas. From the previous study conducted in TGA-DSC emerged that K-feldspar was optimal for both arboreal and herbaceous biomass, while the olivine was optimal only for arboreal biomass. From the present analysis, it is clear that olivine is the one that tends most easily to contribute to the contamination of syngas in terms of heavy metals (such as Ni, Cu, Zn, Cd, Sn, Ba and Pb), while K-feldspar allows obtaining a cleaner syngas. An exception is represented by Cr, whose presence is detected only in tests carried out using K-feldspar. This data is in accordance with lab-scale tests. As for the organic contaminants tar and VOCs, there is no substantial difference between the two FBG bed materials used, except for Benzo[b]fluoranthene whose concentration in the syngas produced using K-feldspar is approximately 20 times higher than that detected using olivine. In conclusion, the behavior of such materials was again monitored in a pilot gasification plant using the arboreal biomass of almond shells which can then be used as a new energy source from a circular economy perspective. K-feldspar, besides being a minor metal emitter, shows a higher capacity in combination with biomass to produce a syngas richer in H2.