MINIMUM QUALITY STANDARDS FOR BIOMASS GASIFICATION PLANTS

Policy Advisory Services in Biomass Gasification Technology in Pakistan MINIMUM QUALITY STANDARDS FOR BIOMASS GASIFICATION PLANTS VERSION (3) -FINAL Submitted to UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION Submitted by DEVELOPMENT ENVIRONERGY SERVICES LTD 819, Antriksh Bhawan, 22 Kasturba Gandhi Marg, New Delhi -110001 Tel.: +91 11 4079 1100 Fax : +91 11 4079 1101; www.deslenergy.com May 2017

DISCLAIMERThis report (including any enclosures and attachments) has been prepared for the exclusive use andbenefit of the addressee(s) and solely for the purpose for which it is provided. Unless we provideexpress prior written consent, no part of this report should be reproduced, distributed or communicatedto any third party. We do not accept any liability if this report is used for an alternative purpose fromwhich it is intended, nor to any third party in respect of this reportClient Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 2 of 52

ACKNOWLEDGEMENTThis document has been prepared for the United Nations Industrial Development Organization (UNIDO)under the project title “Policy advisory services (Biomass gasification technologies)” under the SAP ID100333: “Promoting sustainable energy production and use for biomass in Pakistan”.Development Environergy Services Ltd. (DESL) acknowledges the consistent support provided by thefollowing UNIDO officials:• Mr. Alois Mhlanga, Project Manager• Mr. Ali Yasir, National Project Manager, Sustainable Energy, Biomass - Pakistan• Mr. Masroor Ahmed Khan, National Project Manager, Sustainable Energy RE & EEStudy Team Dr. GC Datta Roy, DESL , India Mr. R Rajmohan, Biomass technology expert, DESL, IndiaTeam leader Mr. Qazi Sabir, PITCO, PakistanTeam member(s)Client Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 3 of 52

TABLE OF CONTENTSEXECUTIV E SUMMARY ...................................................................................................................................................................81 INTRODUCTION ....................................................................................................................................................................10 1.1 OVERVIEW.......................................................................................................................................................................10 1.2 SCOPE OF WORK ..............................................................................................................................................................10 1.3 METHODOLOGY...............................................................................................................................................................11 1.4 STRUCTURE OF THE REPORT..............................................................................................................................................111 BIOMASS ENERGY TECHNOLOGIES ..................................................................................................................................13 1.1 COMBUSTION BASED RANKINE SYSTEM .............................................................................................................................13 1.2 GASIFICATION AND GAS ENGINE BASED SYSTEM .................................................................................................................142 TECHNICAL STANDARDS & DATA SHEETS ......................................................................................................................16 2.1 MINIMUM PERFORMANCE STANDARDS.............................................................................................................................16 2.2 TECHNICAL PERFORMANCE STANDARDS.............................................................................................................................16 2.3 TECHNICAL DATA SHEETS..................................................................................................................................................173 QUALITY STANDARD-MANUFACTURING & TESTING ...................................................................................................214 SAFETY CONSIDERATIONS .................................................................................................................................................235 ANNEXES................................................................................................................................................................................24 5.1 ANNEX-1: TERMS OF REFERENCE AND STAKEHOLDERS CONSULTED.....................................................................................24 5.2 ANNEX -2: BIOMASS GASIFICATION TECHNOLOGIES & EQUIPMENT ....................................................................................26 5.3 ANNEX-3: STANDARDS & CODES.....................................................................................................................................41 5.4 ANNEX-4: MANUFACTURING QUALITY STANDARD.............................................................................................................42 5.5 ANNEX-5: GOOD ENGINEERING PRACTICES.......................................................................................................................49 5.6 ANNEX-6: DEFINITIONS OF TERMS....................................................................................................................................52Client Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 4 of 52

LIST OF TABLESTABLE 1: PERFORMANCE STANDARDS-CERC REGULATIONS 2014.........................................................................................................16TABLE 2: RECOMMENDED PERFORMANCE STANDARDS..........................................................................................................................17TABLE 3: TECHNICAL DATA SHEET-BOILER.............................................................................................................................................18TABLE 4: TECHNICAL DATA SHEET-TURBO-GENERATOR SET....................................................................................................................18TABLE 5: TECHNICAL DATA SHEET-GASIFIER INCLUDING GAS CLEAN UP SYSTEM ......................................................................................19TABLE 6: TECHNICAL DATA SHEET-GAS ENGINE.....................................................................................................................................20TABLE 7: RELEVANT PAKISTAN STANDARDS...........................................................................................................................................21TABLE 8: FUEL PROPERTIES FOR FIXED BED GASIFIER..............................................................................................................................26TABLE 9: FUEL CHARACTERISTICS-REQUIREMENT FOR FLUIDIZED BED GASIFIER8 ......................................................................................27TABLE 10: CLEANING SYSTEMS.............................................................................................................................................................32TABLE 11: TYPICAL CHARACTERISTICS OF PRODUCER GAS COMPARED TO OTHER GASES...........................................................................35TABLE 12: FACTORS AFFECTING GAS QUALITY .......................................................................................................................................37TABLE 13: MAXIMUM TEMPERATURE OF ANCHOR TIPS.........................................................................................................................44TABLE 14: INSTRUMENTATION AND AUXILIARY CONNECTIONS...............................................................................................................48 LIST OF FIG URESFIGURE 1: WORK METHODOLOGY........................................................................................................................................................11FIGURE 2: SCHEMATIC REPRESENTATION OF RANKINE CYCLE.................................................................................................................13FIGURE 3: SCHEMATIC DIAGRAM OF GASIFIER COUPLED WITH PRODUCER GAS BASED GENERATOR SETS................................................14FIGURE 4: PROCESS OF GASIFICATION...................................................................................................................................................14FIGURE 5: DIFFERENT GASIFICATION TECHNOLOGIES.............................................................................................................................26FIGURE 6: TYPES OF FIXED BED GASIFIERS.............................................................................................................................................27FIGURE 7: FLUIDIZED BED GASIFICATION...............................................................................................................................................28FIGURE 8: GASIFIER SIZE BY TYPE..........................................................................................................................................................28FIGURE 9: TYPICAL PROCESS CHAIN OF A BIOMASS GASIFICATION PLANT.................................................................................................29FIGURE 10: CYCLONE SEPARATOR ........................................................................................................................................................33FIGURE 11: WET SCRUBBING SYSTEM...................................................................................................................................................34Client Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 5 of 52

AED B ABB REV IA TIONSANSIAPC Alternative Energy Development Board American National Standards InstituteAPTMA Air Pollution ControlASME All Pakistan Textile Mills AssociationAS TM American Society of Mechanical Engineers American Society for Testing And MaterialsBGP Biomass gasification plantBGTs Biomass Gasification TechnologiesBIS Bureau of Indian StandardsCERC Central Electricity Regulatory Commission MethaneCH 4 Combined heat and powerCHP Carbon MonoxideCO Carbon DioxideCO 2 Central Power Purchasing Agency (Guarantee)CPPA-G Cast steelCS Development Environergy Services Ltd.DESL Dye Penetrant Electric resistance weldingDP Electrostatic PrecipitatorERW European UnionESP Food and Agriculture OrganizationEU Fluidized Bed Combustion Gross Calorific ValueFAO Gross development productFBC HydrogenGCV Hydrogen Sulphide Hazard and Operability StudyGDP Hydrochloric acidH2 Health, Safety and EnvironmentH2S International Electrotechnical CommissionHAZOP International Organization for Standardization Maximum continuous ratingHCl Material of ConstructionHSE Magnetic ParticleIEC Medium Term Development FrameworkISO Ni trogen Non-Destructive TestingMCR National Electric Power Regulatory AuthorityMOC Operation and MaintenanceMP Pakistan Agriculture and Dairy Farmers Association Polycyclic Aromatic HydrocarbonsMTDF PITCO (P) Ltd., PakistanN2 Programmable Logic ControllerNDT Pakistan StandardNEPR A Pakistan Sugar Mills Association Pakistan Standards and Quality Control authorityO&M Rice Exporters Association of PakistanPADF A Society of Automobile EngineersPAH State Bank of PakistanPITCO Superheated/ super heaterPLCPSPSMAPSQCAREAPSAESBPSHClient Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 6 of 52

SME Small Medium EnterprisesSMED A Small and Medium Enterprises Development AuthoritySS Stainless steelTG Traveling grateUNIDO United Nations Industrial Development OrganizationUPS Uninterrupted Power Supply UNITS OF MEASUREMENTSParameters Uni tAt mos pher eCenti m et er atmDegree Celsius cmFa hrenhei tHours °CInch Water Column °FKilo CalorieKilogram/ square Centimeter HKil ogra m/hour WCKilo Newton/ square meterKilo Watt kCalMega Watt kg/cm2Mega Joule/kilogramMega Joule/Newton cubic meter kg/hMi crometer kN/ m2Milligram/Newton cubic meterMi lli meter kWParts Per MillionTons per hour MW MJ/kg MJ/Nm3 µm mg/ Nm3 mm ppm TPHClient Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 7 of 52

Executive SummaryThe United Nations Industrial Development Organization (UNIDO) is implementing the “PromotingSustainable Production and Use from Biomass in Pakistan” project, with the goal to promote marketbased adoption of modern biomass energy technologies in industries in Pakistan. Under this project,UNIDO is working with the Alternative Energy Development Board, (AEDB), Government of Pakistan, todevelop policy and incentives which will help stimulate market based uptake of biomass energytechnologies, including the development of minimum quality standards.Minimum quality standardsQuality standards typically comprise: performance standards, standard formats for specification ofequipment and manufacturing standards.Performance standards Specifications Manufacturing standardsSetting performance standards and technical specifications play much more important role in the initialstages of market development. Manufacturing quality standards are required much later in the journeywhen the market size is large enough to support local manufacturing capability.For example, Europe has led the first major effort for development of an international protocol forbiomass gasifier, with a two year initiative from 2007-09 leading to the development of guidelines forenvironmental and safe operations of biomass gasifiers. In India, biomass gasification system has beenoperating for over two decades; yet, the draft standards have been developed only in 2014.Performance standards and technical data sheets have therefore, been given primacy and constitute themain body of the report. A brief review of manufacturing quality standard has also been provided in themain body of the report. More detailed notes on manufacturing quality standards and good engineeringpractices have been prepared capturing the important and relevant provisions from the EU and Indiandrafts (included as Annex).Who needs themVarious stakeholders use ‘minimum quality standards’ for different purposes. Policy makers andregulators, user standards for qualifying projects for promotional support. Subsequently fiscal andmonetary authorities, use standards for verification of equipment and systems for management ofincentive schemes. Manufacturers of equipment and systems need quality standards for setting up theirquality management process, and project developers use the standards for preparing procurementspecifications and subsequently ensuring the plant operation as per required safety and efficiencynorms.Client Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 8 of 52

Policy makers Financial Manufacturers Project Plant operators& Regulators administration developers •To set up •Monitor •Qualifying •Verification quality •For efficiency projects for of managemen preparing and safety in promotional equipment t process procurement operations support and systems specifictions for managemen t of incentive schemesThis report includes specific information and technical data sheets with a view to assist:• AEDB: to set the technical criteria for qualifying biomass energy projects for promotional support under various Government schemes• Prospective project developers in preparing their procurement specification sheets for key components for a project to deliver the target outputs and efficienciesRecommended approach for development of setting standards for PakistanThe process of prescribing minimum quality standard in Pakistan can be set in motion by introducingminimum performance standards for projects and then introduction of more comprehensive standardscovering all aspects-manufacture, construction and operation and maintenance. Further, most of theequipment and systems required for biomass energy projects are already covered under differentPakistan or international Standards (Annex-3). Equipment for which such standards are not available canbe covered by manufacturers/exporters defined quality standards and inspection report until such timePakistan institutes its own standards for these.Client Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 9 of 52

1 Introduction1.1 OverviewPakistan is endowed with abundant availability of biomass resources, which can be economicallydeployed for developing a sustainable biomass energy system. The country has been perennially facingpower demand-supply gap, which is currently estimated at 4,500 to 5,500 MW 1. The system is beingmaintained by resorting to load shedding; often extending to 12 to 16 hours2. Pakistan has plans to add9,700 MW of electricity generation capacity by 2030 as per the Medium-Term Development Framework(MTDF)2, which would partly take care of the current shortages. It would be necessary to expand anddiversify the resource base; particularly in the context of universal access to electricity in all regions ofthe country. Industries in Pakistan are currently dependent on liquid fuels for meeting their captivedemand for electricity and heat. The situation is therefore, ideally suited for promoting biomass energysystem as a sustainable and renewable alternative for industries. Power generation through biomass canalso play an important role in bridging the overall demand-supply gap and universal energy access.Considering the potential contribution of biomass energy system to the power sector, the UnitedNations Industrial Development Organization (UNIDO) is providing technical assistance to and workingwith Government of Pakistan for promoting biomass energy technologies in Pakistan. Small and mediumenterprises (SME) in Pakistan constitute 90% of the industrial enterprises and contribute to 40% of GDP.Electricity supply to SME’s is also erratic and inadequate. A number of the industries have high demandfor process heat too. Many SMEs are looking for alternative solutions for energy supply to achieveenergy security, including biomass energy technologies.UNIDO has contracted the Consultant through an international competitive bidding process forproviding various services including: • recommendations on policy support, incentives, implementation rules and regulations under RE Policy 2006 (and amendment of 2013) for the Alternative Energy Development Board (AEDB) and capacity building; • recommendations on biomass pricing mechanism based on internationally accepted and successful practices; and • development of minimum quality standards for biomass combustion and gasification equipment for import and local manufacture1.2 Scope of workThe scope of work (detailed scope is included in Annex-1) included among other tasks, providingrecommendations for the minimum quality and performance standards for import and localmanufacture of biomass energy systems.1 National Power Policy 2013, Government of Pakistan2 Policy for development of renewable energy for power generation, Government of Pakistan, 2006Client Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 10 of 52

1.3 MethodologyThe scope of work was accomplished in a sequential manner as illustrated below.Preparation of •Desk research on global development the 1st draft •Preparation of the draft for consultation with UNIDO •Revision of draft and circulation to key stakeholdersStakeholders •Identification of key stakeholders & circulation of list for endorsement from UNIDOconsultation •Interaction meetings with individual stakeholders •Collation and circulation of report on inputs from stakeholdersPreparation of •Consultation with UNIDO & AEDB on feedback report 2nd draft •Finalisation of key points for inclusion in the revised report •Preparation of second draftStakeholders •Finalisation of stakeholders list for the national workshop workshop •Preparation of workshop agenda in consultation with UNIDO •Assist UNIDO in organising the workshop •Summarizing discussions and feedback from participants •Revision of report based on feedbackSubmission of •Submission of final report along with recommendations on implementation measures final report Figure 1: Work methodologyThe first draft of this report, on quality standards, was prepared based on desk research, review ofglobal case studies on quality standards (Jan-16). Based on initial feedback from UNIDO and AlternativeEnergy Development Board (AEDB), the first draft was revised (Feb-Jun-16). The revised first draft wasthen discussed with the key stakeholders through one-on-one consultations (Jul-Nov-16), and a finaldraft report was prepared (Dec-16) addressing the feedback and suggestions received during theseconsultations. Finally, a stakeholder consultation workshop was organized at Islamabad on 13th April, 17during which further comments were received, which have been incorporated in this final report.1.4 Structure of the reportThe structure of this report is as follows: • Section 2: Brief review of the biomass combustion and gasification technologies • Section 3: Technical standards & data sheets • Section 4: Quality standard-manufacturing & testingClient Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 11 of 52

• Section 5: Safety• Annex-1: Terms of reference and stakeholders consulted• Annex-2: Detailed presentation on biomass gasification technology including case studies• Annex-3: Standards and codes• Annex-4: Summary on manufacturing quality standards for gasifiers• Annex-5: Good engineering practices-gasifiers• Annex-7: Definitions of terminologies used for gasification plantsClient Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 12 of 52

1 Biomass energy technologiesBiomass resources are amenable to application of a wide array of conversion technologies for producingthermal and electrical energy. In the context of the terms of reference for the project, these can bebroadly categorized under two different models: • Combustion based Rankine system • Gasification and gas engine based system1.1 Combustion based Rankine systemThe combustion-based systems are most versatile and can utilize all kinds of biomass resourcesincluding wastes. Biomass is fired in a boiler to produce steam and the same is used in steam turbine forgeneration of power.The technology and specifications of the various components of the project are quite akin to normalthermal power plants except for the boiler. Several technologies have been developed for biomass-firedboilers considering the biomass characteristics and the plant capacity. Traveling grate (TG) is the mostversatile as it can practically handle all kinds of biomasses. However, efficiency of this technology islower as compared to fluidized based system. The fluidized bed combustion (FBC) system is highlysensitive to physical and chemical qualities of fuel. FBC technology is a preferred option for grainybiomasses such as chips, shells and rice husks due to high efficiency performance. Traveling gratetechnology on the other hand, is a better option for other types of leafy and non-uniform biomassessuch as stalks and straws, bagasse etc. Figure 2: Schematic Representation of Rankine CycleThe capacity of such projects usually range from about 1 MW to 10 MW except for bagasse, wherehigher capacity projects can be configured based on cane crushing capacity and bagasse generation. TheClient Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 13 of 52

techno-economic consideration decides the lower limit, whereas the higher limit is governed byavailability of fuel within the catchment area of the project.1.2 Gasification and gas engine based systemSmaller projects of size ranging from few kWs to about one (1) MW can be developed under thedecentralized distributed generation concept based on gasification technologies. Biomass gasification isthe process of partial combustion of biomass under controlled air supply, thus producing a mixture ofgases generally called as producer gas. Biomass gasification projects would be based on locally availablebiomass resources thereby reducing the fuel management cost as well as carbon footprint as a verysmall quantity of fuel would be required for transportation of biomass. Such projects can be developedboth on grid-connected and off-grid mode as captive projects for industries and energy access projectsin the rural areas.In gasification process, biomasses such as rice husk, wood, cotton sticks etc. are gasified (incompletecombustion with air) to produce so called ´producer gas´ containing carbon monoxide, hydrogen,methane and some other inert gases. Figure 3: Schematic Diagram of Gasifier coupled with Producer Gas Based Generator SetsThere are four main sub-processes in gasification, which are described below3:• This includes the Pyrolysis •Air is introduced Reduction removal of in a gasifier in the moisture from •After biomass is oxidation zone. •Reducing fuel & conversion heated, it The oxidation conditions, the into steam. undergoes takes place at following pyrolysis- the about 700-1400°C reactions take Drying thermal place resulting in decomposition in Oxidation formation of CO, the absence of O2 H2, and CH4. Figure 4: Process of gasification3Biomass Gasification, Biomass Knowledge Portal [http://biomasspower.gov.in/document/download-lef-ts i de/Bi omass %20gasi fica ti on.pdf]Client Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 14 of 52

Gasification of coal and woody biomass is over 75 years old and matured technology. A number ofinstitutions have been working globally to improve the technology more efficient and versatile with aview to utilize locally available biomasses in cost effective manner. The gross calorific value (GCV) ofproducer gas is very low at about 1,000 kCal/m3 (4,184 kJ/m3) against 10,000 kCal/m3 (41.84 MJ/m3) forpetroleum gases. Thus, a much higher volume of the gas engine is required for producing the sameamount of power. The engines are specifically designed for utilizing producer gas as fuel. The gasgenerated in the reactor contains harmful impurities such as particulates, tar, etc., which are harmful forgas engines. Gas clean up system must be therefore, designed specifically for fuel types.A more detailed description on the gasification technology has been annexed (Annex-2).Client Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 15 of 52

2 Technical standards & data sheets2.1 Minimum performance standardsSetting the overall performance standards and the broad specifications of major equipment usuallyserve the purpose of ‘minimum quality standard’ from the policy and regulatory perspectives.2.2 Technical performance standardsIt is quite challenging to set the overall performance standard for biomass energy technologies due todiversity factors. Both physical and chemical characteristics vary widely for different types of biomasses.The GCV varies from about 2,000 kCal/kg (8,368 kJ/kg) for bagasse to close to 6,000 kCal/kg (25 MJ/kg)for nutshells. Size distribution is uniform for rice husk but vary widely for bagasse, straws etc. Moisturein bagasse is over 50% but is as low as 5% in case of nutshells. Ash on the other hand is extremely low inbagasse at 2 to 3% compared to over 15% for rice husk. These variations have direct impact on choice ofconversion technologies and consequently conversion efficiencies.The regulators in India, both at the federal and provincial levels, have been continuously addressingthese issues for determination of feed-in-tariffs. Based on extensive research and public deliberations,Central Electricity Regulatory Commission (CERC) in India has taken the pioneering initiative of settingthe performance standards for different biomass fuel and technologies in 20144, key performanceparameters are shown in the following table.Table 1: Performance standards-CERC regulations 2014 Unit Boiler Values 3,100 GasificationS. No. Parameters kCal/kg 3,100 4,125 -1 Fuel calorific value kCal/kWh 4,2002 Overall heat rate kCal/kWh 1.25 kg/kWh - 10 Fluidized bed Traveling grate % 103 Specific fuel consumption % 124 Auxiliary power consumption Water cooled condenser Air cooled condenserBiomass energy systems have been operating in India for over three decades. Conversion technologiesand operation and maintenance (O&M) practices have significantly improved over the years. Theperformance standards determined by the CERC take into account these improvements and thespecified values are almost the global benchmark.We have provided consulting, engineering & O&M improvement services for a large number of biomassenergy projects. Very few of these projects have been able to achieve the above standards. We wouldtherefore recommend fixing of standards that are more liberal during the initial stage of development of4The RE Tariff Regulations-CERC India, 15th May 2014Client Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 16 of 52

biomass energy technologies in Pakistan. Our proposed recommendations for Pakistan, comparedagainst corresponding values from CERC regulation and information from projects in our database aresummarized in the table belowTable 2: Recommended performance standardsSl No Parameters Unit CERC DESL Data Recommended base A Combustion Technologies (Boiler/ Turbo-Generator)1 Fuel calorific value kCal/kg 3,100 3.100 3,1002 Overall heat rate(i) Traveling grate boiler kCal/kWh 4,200 4,500-5,000 4,500(ii) Fluidized bed boiler kCal/kWh 4,125 3,800-4,250 4,2003 Auxiliary power consumption(i) Air cooled % 12 13-15 14(ii) Water cooled % 10 12-14 12 B Gasification Technologies1 Fuel calorific value kCal/kg 3,100 3.100 3,1002 Overall heat rate(i) Updraft gasifier kCal/kWh - 4,600-5,000 4,600(ii) Downdraft gasifier kCal/kWh - 5,280 5,2803 Specific fuel consumption kg/kWh 1.25 1.5-2.5 1.84 Auxiliary power consumption % 10 10 10For calorific value of fuel ranging between 2,500 to 4,000 kCal/kg (10.5-16.75 MJ/kg) , the calorific valueof producer gas will vary between 670 to 1,070 kCal/Nm3 (2.80-4.35 MJ/Nm3).2.3 Technical data sheetsThe key components for the two types of major biomass energy technologies are: • Combustion system o Boiler including air pollution control (APC) system o Turbo-generator unit • Gasification system o Gasifier including gas clean up system o Engine generatorsCommon items for all types of projects would include: • Fuel preparation and handling system • Ash handling system • Water system • Electrical and instrumentation systemFor the purpose of this report, technical data sheets have been prepared for the major components i.e.boiler including APC, turbine, gasifier, gas clean up system and gas engine.Client Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 17 of 52

The technical data sheets for the major components have been prepared capturing the minimumspecification requirements from performance perspectives and presented in the following sub-sections.3.3.1 Combustion systemsThe technical data sheet for combustion system i.e. boiler and turbine are tabulated below5.Table 3: Technical data sheet-boiler Units Value NameS.No. Description 45-65 kCal/kg 410-4801 Biomass fuel type (Rice husk, wood chips, corn cobs, straw, stalks, bagasse, others) kg / h kg / cm2 (g)2 Fuel gross calorific value oC %3 Fuel ultimate analysis*4 MCR Evaporation (Gross)5 SH Steam pressure at main steam stop valve outlet#6 Steam temperature at main steam stop valve outlet#7 Peak capacity of the boiler as a % of MCR capacity&8 Turn down ratio – travelling grate % 50-100 Turn down ratio – fluidized bed % 70-1009 Boiler outlet flue gas temperature oC <16010 Thermal efficiency at GCV % >6811 Dust concentration at boiler outlet @ mg/Nm3 10012 Auxiliary power consumption kW• The scope of supply would include the entire island including feed water and steam system, fuel and ash handling system and air and flue gas system and electrical and instrumentation and control system• Material of construction- as per relevant ASTM and Pakistan Boiler Regulations standard. Vendor to specify fordifferent sections of the boiler• Manufacturing & testing standards-As per relevant ASME code* To be specified by the project proponent** To be specified as per techno-economic feasibility report# To be determined as per techno-economic feasibility report. However, project at pressure <45 bar andtemperature < 410oC to be discouraged&Vendor to specify@ (multi cyclone for traveling grate boilers of capacity <10 TPH, electro static precipitator or bag filters for restTable 4: Technical data sheet-Turbo-generator setS.No. Description Units Value MW1 Model2 Capacity*3 Configuration (Condensing/Bleed condensing/Extraction condensing/Back pressure*)4 Type (Reaction/Mixed/Impulse) **5 Number of stages*** Number5 Values are illustrative based on projects in our database, specifications in this format is recommendedto be sought from vendorsClient Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 18 of 52

S.No. Description Units Value6 Inlet steam pressure kg / cm2 (g) (5% less than the SH steam pressure at the boiler outlet) 507 Inlet steam temperature oC 35 (10o C less than the SH steam temperature at the boiler outlet)8 Extraction/Bleed pressure* kg / cm2 (g)9 kg / cm2 (g)10 Exhaust/Back pressure* %11 Turn down ratio*** kg/kWh12 Specific steam consumption at 100% and 50% load *** kW13 Auxiliary power consumption*** oC Cooling water temperature for the condensing plant• The scope of supply would include the entire island including turbo-generator unit with its auxiliaries, condensing plant along with cooling water system and the electrical and instrumentation and control system• Manufacturing & testing standards-As per relevant ASME code for turbine & IEC 34 for alternator; all electrical items to be as per IP 54 and F-class insulation* To be specified as per techno-economic feasibility report** Impulse turbine to be allowed only for very low capacity machines** Vendor to specify3.3.2 Technical data sheet – Gasification systemThe technical data sheet for gasification system i.e. gasifier including clean up system and gas engine aretabulated below.Table 5: Technical data sheet-Gasifier including gas clean up system Units ValueS.No. Description % <201 Biomass fuel type (Rice husk, wood chips, corn cobs, stalks, % <15 others) Downdraft2 Fuel moisture3 Fuel ash oC 1000-11004 Model5 Type of gasifier atm6 Rector conditions Nm3/h Temperature CO-15+/-3, H2-20+/-5 Pressure CO 2-13+/-37 Peak gas flow rate*8 Gas composition (%) CH4 -1-4 kCal/Nm3 >10509 Calorific value of gas10 Peak rated thermal output kCal/h11 Average rated thermal output12 Gasification temperature kCal/h 850-95013 Gas temperature at gasifier outlet oC 300-50014 Gasification thermal efficiency (hot gas mode) oC15 Gasification thermal efficiency (cold gas mode)16 Specific fuel consumption % >80 % >70 kg/Nm3Client Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 19 of 52

S.No. Description Units Value17 Turn down ratio % <5018 Auxiliary power consumption kWGas clean up system19 Type Wet20 Filter material life h >100021 Interval between cleaning h >5022 Particulate concentration in clean gas mg/Nm3 <1523 Tar content in clean gas mg/Nm3 <1524 Temperature of inlet gas to engine oC <40• The scope of supply would include the entire electro-mechanical system including fuel processing and feeding and ash removal systems and treatment plant for the liquid effluent• The hopper & body shall be of MS/SS/Ceramic with a minimum life of 5 years.• Reaction cone, throat and nozzles shall be of SS310/316/refractory/ceramic or high alumina and high temperature bricks* To be specified in techno-economic feasibility studyTable 6: Technical data sheet-Gas engineS.No. Description Units Value1 Fuel input (Biomass producer gas) CV kCal/Nm3 >10502 Particulate concentration in clean gas mg/Nm3 <153 Tar content in clean gas mg/Nm3 <15 <404 Temperature of inlet gas to engine oC 0.855 Model6 Capacity* kVA7 Power factor Ratio8 Auxiliary power consumption** %9 Assured duty cycle & operating hours** /year • Conforming to relevant National Environmental Quality Standards for Gaseous Emission* to be specified in the techno-economi c feasibility s tudy** vendor to specifyMore detailed description of the various components of the gasification system have been provided inAnnex-2, taking into consideration that the technology is at the nascent stage of development in thePakistan market.Client Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 20 of 52

3 Quality Standard-Manufacturing & testingWell established international (IEC, ISO) and national standards exist for manufacturing quality andtesting protocols for equipment such as boilers, turbo-generator sets, gas engine generators. Thefollowing table illustrates the Pakistan standards, which are applicable for equipment relevant to thebiomass energy projects except for a few systems such as gasifier.Table 7: Relevant Pakistan standards Legal provisions in Pakistan S.R.O.742(I)/93Examples of application S.R.O.742(I)/93Quality of municipal and liquid industrial effluents PS #1666-1985Quality of industrial gaseous emissions PS #4158-1998,Electrical instruments, drives, control systems, generator PS #2199-1989Electrical instruments, drives, control systems PS # 2433-1989Drives, pumps, blowers, moving mechanical parts, gas engine, S.R.O. 1062(I)2010fuel feeding system, ash removal system PS 2383-1989Noise PS 2377-1989Heat exchangers/boilers, compressed air systemConveyor beltsASME VIII and ASME PTC (different sections) codes are widely utilized for boilers and turbines (alongwith IEC 34) across the globe including Pakistan. These standards can continue to be used for biomassenergy projects too. A comprehensive list of standards and codes which are applicable for biomassenergy systems is included in Annex-3.It appears that no international comprehensive code has been developed for biomass gasifiers. Projectspecific manuals have often been used primarily for monitoring of performance of donor-fundedprojects. These have mostly dealt with construction and operation quality management as per theprotocol developed for the project such as World Bank sponsored CHP project in China and FAOsponsored biogas project in Nepal6. A few specific testing protocols have been developed for particularaspects of technology (for example ASTM standard for tar testing). An EU project “Guideline for safeand eco-friendly biomass gasification”, Intelligent Energy for Europe Program, supported by theEuropean Commission seemed to have been the first major efforts towards development of aninternational protocol on biomass gasifier. Several institutions in Europe were involved in developingthe protocol over two year’s period from 2007 to 2009. However, the focus of this program wasenvironmental and safety aspects of operation of biomass gasifier.“The objective of the gasification guide project is to accelerate the market penetration of small-scalebiomass gasification systems (< 5 MW fuel power) by the development of a guideline and software toolto facilitate risk assessment of HSE aspects. The guideline may also be applied in retrofitting orconverting old thermal plants in the Eastern European countries – with rich biomass resources – to newgasification plants. The objective of this document is to guide key target groups identifying potential6FAO/TCP/NEP/4415-T for Nepal Bio-gas program in the ninetiesClient Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 21 of 52

hazards and make a proper risk assessment. The software tool is an additional aid in the riskassessment”7Based on review of information available in the public domain, it appears that the most comprehensiveand recent efforts for development of standard for biomass gasification system has been made in Indiaresulting in preparation of a draft protocol in 20148. Ministry of New & Renewable Energy, Governmentof India had sponsored the program “advancement of research on biomass conversion technology andend use devices” for wider adaptation of biomass energy by the industrial sector. Development ofspecifications and standards for biomass energy devices and technical support for establishing testcenter were amongst the key objectives of the program.A number of specific protocols have been developed and forwarded to the Bureau of Indian Standard(BIS) for development of a BIS document on biomass gasifier. Key amongst them include: • General information covering engineering practices • Specific protocols on safety such as gas flaring etc. • Design considerations • Manufacturing tolerances • Specifications • Test procedures • Data sheets & reporting formatsThe Indian protocol has been developed primarily for the manufacturers of gasifiers whereas the focusof EU document is more on environment and safety aspects of construction and operation of gasifiers.At the current stage of development in Pakistan, it may not be that relevant to adopt such detailedquality protocol. A step-by-step process may be adopted as follows: • Issue of notification on overall performance specifications for promotion of biomass energy technologies • Standardization of technical data sheets for the key components • Issue of notification on safety in work place deploying biomass gasifierA capsule summary on manufacturing quality standard and good engineering practices have beenprepared capturing the relevant provisions in the EU and Indian documents and included at Annex-4 andAnnex-5 respectively.7Gasification guide-Intelligent Energy-Europe8Report of ABRC-CGPL, Department of Aerospace, IPSC, Bangalore, India, 2014Client Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 22 of 52

4 Safety considerationsGeneral safety guidelines for operation of gasifier units: • Online oxygen sensors should be installed in the gasifier plant and online carbon-mono-oxide (CO) monitors should installed around the plant • Fixed online CO-detectors should be installed in fuel storage buildings, gasifier building, gas engine room (or noise hood) • CO monitors should be installed in control rooms, if the same does not have positive pressure ventilation • A number of small portable CO monitors giving indication and alarm should be kept in the control room and should be provided to operators working in the area • Fire detection system and sprinkler system should be provided for the gasifier unit • Automatic water spraying system should be provided on ash discharged from the gasifier reactor • Fuel for gasifier should be stored in a separate room/are • Ventilation system should be well maintained to ensure adequate operations • Portable fire extinguishers should be available near gasifier unit • All motors depending on hazard, are classified. -Classification should be flame proof/increased safety for the gasifier unit • The following plant sections are recommended to be considered for occurrence of an ex-zone. o Fuel storage and feeding with respect to dust explosions o Fuel intake o Ash and dust removal system o Waste water removal system o Flare and auxiliary firing system (e.g. misfiring) o Engine and exhaust gas system o Manholes and sampling ports o Measurement and instrumentation pointsClient Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 23 of 52

5 Annexes5.1 Annex-1: Terms of reference and stakeholders consulted5.1.1 Terms of referenceObjectives of the Study: The objective of the assignment is to provide advisory services andrecommendations for incentivizing investment in modern biomass conversion technologies, particularlyBiomass Gasification Technologies (BGTs), to the Alternative Energy Development Board (AEDB) andother relevant stakeholders and to conduct the necessary activities for the establishment of rules andregulations for BGTs under the prevailing RE Policy 2006. The consultancy firm will also provide similarrecommendations to be integrated in other existent policies/plans that could support the promotionand adoption of biomass /BGTs in different sectors of the economy such as power generations,industrial co-generations (combined heat and power) in SME Industries, rural electrification, etc., andthe minimum quality standards for import and local manufacture of biomass gasification equipment.Overall scope of work: The overall scope of work for the project is as below:Main Duties Measurable outputs to be achieved1. Review of existing legislation, analysis Preliminary drafts of IRRs, policy recommendationsand formulation of preliminary drafts for promotion of BGTs, minimum quality standards, recommendations on capacity building for local manufacturers are prepared and shared with relevant organizations for onward discussions during the mission2. Consultations with key stakeholders that Mission plan including dates of meetings andinclude tri-partite meetings between consultations with relevant stakeholders areAEDB, UNIDO and key stakeholders and planned and arranged;consultation sessions to present/ explain Collection and compilation of feedback from thethe recommendations and collect relevant stakeholders during the tri-partitefeedback from a wider range of meetings and half-day sessions in the form ofstakeholders meeting notes and mission report3. Preparation of second drafts of the IRRs, Final drafts of the (i) IRRs, (ii) PolicyRecommendations for other relevant recommendations and (iii) minimum qualitypolicies/ plans standards (iv) recommendations on capacity building for local manufacturers are prepared and shared with stakeholders for onward discussion during the workshop; Concept of the national stakeholder workshop prepared4. Presentation of Final Drafts during a National Stakeholders Workshop conducted andNational Stakeholder Workshop final set of feedback from all relevant stakeholders collected5. Submission of Final Policy document and Final IRRs, policy recommendations, qualityQuality standards standards and recommendations on capacity building for local manufacturers are prepared with all the feedback from the stakeholders incorporated for official endorsementClient Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 24 of 52

5.1.2 Stakeholders consultedStakeholders consulted at various stages include the following: Preliminary consultation (1st draft) Stakeholder workshop (final draft)Government, public se ctor organizations, institutions • Alternative Energy Development Board • Alternative Energy Development Board • Federal Bureau of Revenue • Federal Bureau of Revenue • MoWP • Central Power Purchasing Authority • Central Power Purchasing Authority • National Electric Power Regulatory Authority • National Electric Power Regulatory Authority • Energy Department, Punjab • Energy Department, Punjab • Agriculture Department, Government of • Energy Department, Sindh • Agriculture Department, Sindh Punjab • Energy and Power Department, KPK • State Bank of Pakistan • Agriculture Department, KPK • Small and Medium Enterprises Development • AJK Planning Development Organization • AJK Agriculture Department Authori ty • State Bank of Pakistan • Pakistan Standards for Quality Control • Small and Medium Enterprises Development As s ocia ti on Authori ty • Pakistan Standards for Quality ControlAcademic • National University of Science and Technology As s ocia ti on • University of Agriculture, Faisalabad • MEPCO • LESCOIndustry and trade associations • IESCO • Pakistan Agriculture & Dairy Farmers • NRSP As s ocia ti on • RSPN • All Pakistan Textile Mills Association • NARC/PARC • Pakistan Sugar Mills Association • NEECA • Punjab Bio-Energy Company • NFEH • JDW Group • National University of Science and TechnologyInternational organizations • Pakistan Council of Renewable Energy • GIZ Technol ogi es • Punjab Bio-Energy Company • JDW Group • Faran Sugar Mill • HSML • DESCON • GFG • Islamabad Chamber of Commerce and Industry • IFC • SAARC • USAID • UNRCClient Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 25 of 52

5.2 Annex -2: Biomass gasification technologies & equipment5.2.1 Gasification technologyDifferent types of technologies are being used for gasification of biomass as illustrated in the followingfigure: Fixed Bed Fluidized bed Indirect Heating Downdraft Circulating Steam and Bed Air Updrafft Bubbling Plasma Bed Crossdraft Entrained Flow Figure 5: Different gasification technologiesGenerally, both fixed bed and fluidized bed technologies are being deployed for biomass gasification.Indirect heating technologies are still under development stages, internationally.Fixed bed gasifierIn this technology, the fuel is fed into the chamber as it flows from top to bottom, during which itdecomposes into gases. These gasifiers are differentiated based on the direction of inlet of air withrespect to the exhaust of producer gas from the gasification chamber. These gasifiers can handlemoderate ash and moderate moisture fuel. Properties of biomass, which these gasifiers can handle, aretabulated below:Table 8: Fuel properties for fixed bed gasifier9 Range 5- 100 mmDescriptionSize of fuel <60% <6%Moisture Content in fuel Producer gasAsh content (weight %) 3-5 MJ/kgComposition of GasGCV of Gas 4:1 800-1200 o CTurn down RatioTemperature of operation9Biomass CHP Catalog, EPA CHP Partnership [https://www.epa.gov/sites/production/files/2015-07/documents /bi oma ss _combi ned_hea t _a nd_pow er_ca ta l og_of_t echnol ogi es _5._bi oma ss _conversi on_technol ogi es .pdf]Client Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 26 of 52

The pictorial representation of the fixed bed gasifier is shown below. Figure 6: Types of fixed bed gasifiers10Fluidized bed gasifierIn these types of gasifiers, the biomass fuel is combusted in suspension mode, wherein the pressure ofthe air does the process of fluidization. For fluidization, the biomass needs to be prepared and fed intothe gasification chamber. In bubbling bed, the biomass is gasified in the suspension zone, whereas incirculating fluidized bed the fines are carried by the gas and are circulated back into the furnace. Thesetypes of gasifiers can handle biomass fuel with the following properties:Table 9: Fuel characteristics-requirement for fluidized bed gasifierDescription RangeSize of fuel 0.25-20 mmMoisture Content in fuel <20%Ash content in fuel Low 5-25%Composition of Gas Producer gasGCV of Gas 5-6 MJ/kgTurn down Ratio 3:1Temperature of operation 750-1000 o C10http ://w ww .bi os -bi oenergy.a t/ en/el ectri ci ty-from-bi omass /bi oma ss -gasi fi ca ti on.htmlClient Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 27 of 52

Figure 7: Fluidized bed gasification11One of the key characteristics of gasifiers, in addition to the producer gas that they produce, is the sizerange to which they are suited. The figure below provides details of the typical size for the differenttechnologies: Figure 8: Gasifier size by type12Fixed bed downdraft gasifiers do not scale well above 1 MW in size due to difficulty in maintaininguniform reaction conditions. Fixed bed updraft gasifiers have fewer restrictions on their scale whileatmospheric and pressurized fluidized bed and circulating bed and entrained flow gasifiers can providelarge-scale gasification solutions. The types of gasifiers that are predominantly used at small scale arethe updraft and downdraft ones.11http ://w ww .oi l -gas porta l .com/gasi fi ca ti on-proces s /12Biomass for power generation, RE Technologies Cost Analysis Series, Vol.I: Power Sector, IRENA, June, 2012Client Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 28 of 52

This document is intended to be a source for buyers/users/manufacturers of the technology to verify thetechnical specifications taking into consideration the project requirements. The document highlightsthe prerequisite that needs to be taken care of during manufacturing as well as during procurement ofthe biomass gasifier systems. The document is applicable for fixed bed gasifiers.Biomass gasification plants (BGP) also need to comply with the prevailing environmental and safety laws.In the development of this document, the following systems have been reviewed, • Biomass storage and handling on site • Biomass conveyance and feeding • Gasification reactor • Gas conditioning (cleaning and cooling) • Gas utilization in process heating & power generation • Automation and controls • Auxiliaries and utilities5.2.2 Biomass gasification process chainBiomass gasification with a downstream gas engine is particularly suitable for decentralized biomassutilization and high efficient combined heat and power production. Figure 9 shown below presents asimplified diagram of a biomass gasifier plant illustrating the main components, which describe andclassify the process.Fuel supply/ Gasifier Gas cooling and Gas utilizationstorage cleaning •Fixed bed •Gas engine •Biomass gasification •Cyclone •Gas turbine storage •Fluidized bed •Bag house •Micro gas gasification •Filtering turbine •Utilities Utilities •Water de- •Synthetic fuel storage (water vapor, dusting/ applications air, additives) cleaning •Intermediate •Gasification •Residues storage of boundaries - treatment gasification pressurized, residues atmospheric •Conveying technology •input units or rotary valves, vibro conveyor etc. Figure 9: Typical process chain of a biomass gasification plantBiomass as fuel is fed into the gasification reactor through an air/gas-tight closure (exception is an opentop gasifier) by appropriate fuel conveying systems. The conversion of the biomass fuel into producergas takes place in the gasification reactor, where the thermo-chemical conversion steps of drying;Client Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 29 of 52

pyrolysis, partial oxidation and reduction, and ash formation take place. However, for smaller sizeprojects, currently in commercial operation air is the gasification agent.The producer gas leaves the reactor at elevated temperatures (600-800°C) with a certain heating value.In the subsequent steps of the process chain, sensible heat contained in the producer gas can be usedfor internal process heat, drying of the biomass as well as for industrial heating purposes. In variouscleaning and cooling applications, the producer gas is subjected to dry and/or wet cleaning to achievethe required specifications for the gas engine. However, in case of wet gas cleaning, often the sensibleheat remains unutilized.According to the “Guideline for safe and eco-friendly biomass gasification”, during operation of abiomass gasification plant there is an increased hazard potential due to the fact that a potentiallyexplosive, toxic and combustible gas mixture is produced and consumed. The producer gas and residues(ash, liquids, and exhaust gases) may cause the following major hazards/risks: • Explosion and/or fire • Health damage to humans (poisoning, danger of suffocation, noise, hot surfaces, fire and explosion) • Pollution of the environment and plant vicinitySafety in design and operation therefore, remain a key consideration while promoting biomassgasification technologies.Biomass storage, pre-treatment, transport and feedingBiomass storage, transport and pre-treatment may influence the fuel quality (e.g. drying duringstorage), as well as the gasification process stability (e.g. producer gas quality, stability of heat andpower production, etc.). Biomass is normally stored in a separate building adjacent to the main gasifierbuilding or at a place with suitable cover. In most cases, the size of the storage area is chosen based onthe uncertainty of the fuel procurement mechanism/availability situation. From the storage area,biomass is transported to the pre-treatment section. The main technologies available for pretreatmentof biomass to meet the requirements of the gasification system are drying, sizing or compacting,depending on the origin of the fuel.After pre-treatment, the fuel may be transported to a daily storage bunker. The most common meansof transport of biomass is belt conveyor and screws. From the storage area, the fuel is furthertransported to the feeding system, which is mostly equipped with a dosing unit. The fuel conveyor mayhave integrated features like sieving, a magnetic belt, removal of contaminants and foreign materials,and/or a drying unit. A speed-controlled screw, a double-sluice lock hopper system or a rotary valveusually does the actual feeding of the fuel into the gasification reactor.An important aspect is to avoid the escape of gas through the feeding section during the actual feedingand/or the airing during the same period. Anti-backfiring systems can be used or purging, using inertgases to avoid this risk of potentially explosive atmospheres, as well as physically separating the fuelstorage and gasification reactor, minimizing fire risk potentials.Client Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 30 of 52

Auxiliary fuel and plant utilitiesAuxiliary media/fuels such as natural gas, diesel, etc. and plant utilities such as water for cooling ofproducer gas, electricity for blowers/conveyors/fans are required during normal operation as well asmaintenance period.Gasification reactorThe thermo-chemical conversion of solid biomass into raw producer gas takes place in the gasificationreactor (gasifier). The sequence of the biomass conversion steps of drying, pyrolysis, partial oxidationand reduction depends on the type of gasifier. Recently, concepts have been developed andimplemented where different zones are physically separated. The main reason behind this separation isthe optimization of each step and minimization of the tar production. “Tar” has been operationallydefined in gasification work as the material in the product stream that is condensable in the gasifier or indownstream processing steps or conversion devices. Tar is unpleasant constituents of gas, which tendsto deposit/stick on the equipment causing troublesome operations. At the exit, the producer gascontains desired products and by- products, which are as follows: • Desired products: Producer gas (Mainly H2, CO, CH4, CO2, N2) and ashes with low carbon content • Undesired products: Particulate matter, dust, soot, inorganic (alkali metals) and organic pollutants (tars or PAH, Polycyclic Hydro Carbons)The reactor is a cylindrical vessel made of mild steel, with an inner lining of cold face insulation bricksand ceramic tiles composed largely of alumina. Air nozzles, provided around the combustion zone, arekept open during the running of the system. To allow for uniform air availability across the reacting bed,an additional air nozzle called the central nozzle is directed to the reactor core. A water seal with aremovable cover forms the top of the reactor, which is kept open during the entire operation of thesystem, to facilitate primary air induction and loading of feedstock. A grate is provided at the reactorbottom to hold the char or ash as the case may be, with a mechanism for intermittent extraction ofchar/ash.Gas coolingThe purpose of gas cooling is to decrease gas temperatures to a certain level for: • Producer gas treatment (e.g. condensation of tar at lower temperatures, thereby gas cleaning in bag filters) or • Utilization in the gas engine; cooling increases the energy density of the gasIt is recommended to recover the sensible heat in the gas, which allows the supply of internal processheat (steam supply, evaporation energy, etc.) and the process heat for industrial applications.Gas cooling system consists of direct water impingement cooler, which is meant for cooling the hotgases from the gasifier reactor to ambient for engine applications and scrubbing the gas to remove theentrained tar and particulate matter. When the gasifier system is operated at the rated load, the systemClient Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 31 of 52

requires 80-100m3/h on a continuous basis for a one (1) MW rating. The coolers perform the twinfunctions of cooling and cleaning the producer gas.Gas cleaningGas cleaning is required to meet the specifications set by the engine supplier, even under varyingconditions like gas flow, producer gas compositions, level of contamination, etc. Major contaminants inthe raw producer gas are particulate matter (soot, dust) and tar. Other impurities may include ammonia(which will be converted to NOx during combustion in the engine), HCl, H2S, alkalis, and acids, alldependent much on the process conditions, fuel and type of the gasifier.This sub system consists of a series of quartz based gas filter, a bag filter, a catalytic converter and a finequality paper filter. The purpose of the filtering system is to reduce the quantity of tar, particulatematter and moisture in the gas to levels that are acceptable for direct admission into gas engines.There are different technologies for the gas cleaning: hot gas cleaning, dry cleaning and wet cleaning.There is subsequently a number of equipment to meet the final discharge gas properties. Thus, cleaningsystem must be optimized.Gas generated is in range of 500-600oC. Gas is laden with tar and fly ash. Gas engine requires gas freefrom these impurities thus gas needs to be conditioned and cooled to the desired temperature before itis fed into the engine.Table 10: Cleaning systems13Techniques Temperature(°C) Particle Reduction (%) Tar Reduction (%)Sand bed Filter 10 to 20 70-99 50-97Wash Tower (Gas Scrubber and 50-60 0-98 10 to 25Chiller)Wet electrostatic precipitator 40-50 >99 0-60Fabric filter 130 70-95 0-50Fixed bed Tar absorber 80 NA >95 NA >95Catalytic air cracker 900Cyclone separatorThis is most effective solution to remove the high-density material form low density gas. Gas is blowninto the equipment, centrifugal forces causes heavy dust particles to move outwards and then theycollide with the internal surface of the metal and slides down, whereas gas lighter than dust experiencesless force, moves upwards. Hot gas is used in the cyclone as higher temperature gas is lighter thusproviding the higher cleaning efficiency.This separation causes the reduction of 70-80% of the fines in the gas. Lighter weight fine particles andtar is carried with gas. These are not separated in this stage.13Journal of Applied Fluid Mechanics, Vol. 5, No. 1, pp. 95-103, 2012Client Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 32 of 52

Figure 10: Cyclone separatorGas coolerGas needs to be cooled to the room temperature, as the desired temperature at the inlet of gas engineis ambient. Small quantity of tar condenses during the cooling of gas, and less quantity of fine particlesare removed with water.Wet scrubberCooled gas is made to contact with jet of water. Velocity of water jet carries away the fine particles andwet particles heavy in weight falls down and conveyed with water in the return channel. Moist gas isdischarged from the system. Gas temperature further decreases in this system.Almost all fines are removed in equipment and discharged gas is contains the dust and tar in thepermissible limit of gas engine.Client Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 33 of 52

Figure 11: Wet scrubbing systemGas chillerDischarged gas from the gas cooler is sent to chiller section wherethe temperature is decreased to the range of the gas temperaturerequired for the gas engine.Chilled gas contains moisture and passes through the demister andchilled gas is sent to the receiver, from where it is fed to the engine.Slight amount of tar is condensed and is carried away withdischarged water from the chilling tower. Temperature of thechilled gas is limited to 7-8 oC.This temperature is limited by the gas temperature required at theengine as per SAE norms and engine design. Ambient air and gas temperature needs to be 25oC for bestperformance14.Gas utilizationThe gas engine entails a conditioning of the biomass-derived gas, providing gas parameters determinedby the specifications of the engine (nearly constant producer gas temperature, sufficient heating value,purity level, humidity as well as gas-engine inlet pressure). Gas engine is a commercial commodity,which means that the gasifier manufacturer must fulfill the requirements set by the engine supplier.14Cumin’s Specifi ca tion sheet 240 kWe Producer Gas engineClient Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 34 of 52

BurnerThis is provided to check the initial quality of the combustible gas as also for emergency flaring.Instrumentation & control automationInstrumentation consists of automatic gas flow meter and pressure indicators located on-line to monitorthe quantity and rate of gas production. Instrumentation is also provided for monitoring temperaturesin the reactor, automatic retraction of top cover, automatic start/stop of the bucket elevator, automaticcontrol of gas feed into the engine and automatic char/ash extraction. Relevant parameters such assystem pressures along the gas flow path, gas consumed by the engine and operating parameters suchas pressure, temperature, etc. are also displayed for operational convenience.Computerized data acquisition systemThe following relevant data pertaining to systems operation can be recorded and acquired online on thecomputer: • Reactor temperatures at different zones • Biomass consumption rate • Gas-flow rate • Technical trouble-shooting • Maintenance schedule, both preventive and breakdownAuxiliariesThe plant should incorporate size reduction unit for cutting the biomass into smaller pieces prior tofeeding into the gasifiers. The biomass can be transported with the help of a front-end loader, whichconsists of a tractor provided with front-loading articulated arms fitted with loading bucket, for loadingit onto the hopper of the bucket elevator. Operation of the gasification plant requires loading of biomassinto the reactor in a continuous batch wise basis. A bucket elevator of suitable capacity to facilitatecontinuous loading of biomass into the reactors via two-way chute may be used. Cooling water isrequired for cooling and scrubbing of the gas prior to supply of gas to the engine. To optimize theutilization of limited resources, the system will recycle the wash water. A water treatment plant forcontinuous filtration and purification of water is provided. A cooling tower is provided for cooling therecycled cooling water, after water treatment, to maintain its temperature within the prescribed limits.The system is provided with char extraction unit consisting of a screw blender for intermittent extractionof char/ash. The charcoal, which has commercial value as an industrial adsorbent, is milled to therequired size, bagged and sold.5.2.3 HSE aspectsSmall-scale biomass gasifiers operate normally with air as the gasification agent. This results in a certaingas composition that differs largely from other gases like biogas or natural gas. As per the “Guideline forsafe and eco-friendly biomass gasification”, typical characteristics of producer gas are given in the tablebelow:Table 11: Typical characteristics of producer gas compared to other gasesParameters Producer gasCO (vol %) 12-20Client Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 35 of 52

H2 (vol %) 15-35CH4 (vol %) 1-5CO2 (vol %) 10-15N2 (vol%) 40-50Heating value MJ/Nm3 4.8-6.4Explosion range (vol%) 5-59 1.1-1.5Air to gas ratioControls & safety featuresThe following instrumentation and control systems are desirable for efficient and safe operation of thesystem. 1. Oxygen monitoring system - to indicate if there is any leakage of air into the system, forewarning the operator to take necessary preventive action 2. Water seals - most of the system elements are provided with water seals to release pressure in the event of the system being pressurized. The water seals, with their low-level bubbling noise, also act as adjunct annunciators of system pressure build-up. 3. Automatic reactor shut off - to shut off the reactor automatically in the event of power failure. 4. The automation for start-up consists of a PLC based control system, which controls the following actions • Automatic retraction of top cover with pneumatic arms • Automatic positioning of two-way chute • Automatic cut-on and cut-off of biomass loading in the reactor using ultrasonic sensors • Automatic control of blower operation providing secondary air to the reactor • Automatic extraction of ash from the grate bottom • Automatic control of air blower speed to suit engine requirements • Automatic emergency flaring of gas • Automatic emergency shutdown of reactor5.2.4 Performance considerationsThe following performance considerations are to be taken care of for fixed bed biomass gasifiers15.Cold gas efficiency = Energy content in the gas per kg of biomass/energy content in the biomass.Computation of cold gas efficiency shall be carried out as under: • Compute/measure the gas calorific value per kg of biomass using the gas output rate; biomass feed rate, gas composition and Junker’s calorimeter measurement. • Compute the biomass calorific value using the Bomb calorimeter measurement. Measure cold gas efficiency = Energy content in the gas per kg of biomass/energy content in the biomass.15“Advanced Biomass Research Centre (ABRC)”, Indian Institute of Sciences (IPSc) Bangalore, supported by theMinistry of New & Renewable Energy (MNRE)Client Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 36 of 52

• In case of conflict in the energy content in the gas with respect to computed gas calorific value derived from gas composition and Junker’s calorimeter readings, Junker’s calorimeter reading is to be considered as final.• Computation of calorific valve of both biomass & gas should be done considering biomass moisture content agreed as basis of design/ performance.Gas fed into the engine should conform to the following limits for the impurities.Table 12: Factors affecting gas quality Units Values ppm <5S. No. Factors Affecting ppm <101 Tar 02 Particulate Matter µm 53 Condensate Mg/Nm3 54 Dust Particle –max size5 Dust-Quantity °C Min 5°C bellow gas temperature6 Tar-Dew point5.2.5 Case Studies of operating plants based on different technologiesThere are more than 272 operatinggasification plants worldwide with 686gasifiers. There are currently 74 plantsunder construction worldwide, whichhave total 238 gasifiers producing 83MWth. 33 gasification plants are locatedin the United States. Currently, China hasthe largest number of gasificationplants. Worldwide gasification capacity isexpected to grow significantly by2018, with the primary growth occurringin Asia (primarily China, India, SouthKorea, and Mongolia)16.The details of few biomass gasification plants with advanced technologies are summarized below17.Case -1 : Bioliq Forschungszentrum Karlsruhe (FZK)/Karlsruhe Institut fürTechnologie (KIT), Lurgi GmbHDevelopin gCompanies/ Institutions FZK/LurgiOwnerGasification Technology High temperature entrained-flow gasification of pyrolysis oil, which is produced in a Lurgi fast pyrolysis process to\"Biosyncrude\"16http ://w ww .ga s i fi ca ti on-s yngas .org/res ources /the-ga si fi ca ti on-i ndus try/17Rapport 234 – Biomass Gasifier Database - Jens Hansson,Andreas Leveau och Christian Hulteberg, Nordlight ABAugust 2011Rapport SGC 234 • 1102-7371 • ISRN SGC (Svenskt Gastekniskt Center)Client Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 37 of 52

Primary Purpose Biomass to Fischer-Tropsch fuels, methanol, chemicals, SNGTechnology StatusPower Throughput Demonstration gasifier completed in 2012LocationBrief Description 2 MWth of demonstration unit Karlsruhe, Germany In a joint development between Forschungszentrum Karslruhe (FZK) and Lurgi GmbH, a combined pyrolysis/entrained-flow gasification system has been developed. The idea is to produce a pyrolysis oil (name “BioSynCrude” by Lurgi) on a decentralised location upon which the energy density is increased, where after it is transported to a centralised entrained flow gasification plant wher e it is gasified. Entrained-flow gasification is generally favoured by scale so this is a suitable approach to save on transportation cost and energy.Case -2 : Bioneer Technical Research Centre of Finland (VTT), Bioneer OyDevelopin gCompanies/ Institutions Va ri ousOwner Updraft fixed bedGasification Technology Lime kilns, district heatingPrimary Purpose Commercial system in operation but no new developmentTechnology Status 4-6 MW th inputPower Throughput Kankaanpää, Kempele, Kauhajoki, Hämeenlinna, Parkano,Kitee, Jalasjärvi (Finland)Location and Lit and Vilhelmina (Sweden) The development of an updraft gasifier for peat and wood was initiated at theBrief Description Technical Research Centre of Finland (VTT) in the late 1970s. The idea was to replace imported fuels with domestic. The Finnish Ministry of Trade supported andCase -3 : Harboøre sponsored the venture. During the mid 80s, the VTT conducted extensive tests withDevelopin g a variety of feedstocks, including wood, forest wastes, peat, straw, RDF pellet etc. atCompanies/ Institutions a pilot plant in Kankaanpää. Since 1984 BioneerOy manufactured and sold theOwner gasifiers under the trademark Bioneer. Eight commercial plants were then builtGasification Technology during the 80s, in Finland and Sweden. Yet another commercial plant was built inPrimary Purpose 1996 in Finland.Technology StatusPower Throughput Babcock and Wilcox VølundLocationBrief Description Babcock and Wilcox Vølund Updraft counter-current moving bed gasifier CHP Comm erci al 3.5 MWth input Harboøre, Denmark Danish boiler manufacturer Ansaldo Vølund Energy built the Harboøre updraft countercurrent moving bed gasifier between 1988 and 1992. The updraft technology was chosen to include the drying step in the unit, and to achieve a high carbon conversion. Other benefit would include high heating value of the product gas and low dust content. The plant was actually constructed for district heating only at first but was optimized for gasification in 1997. Gas cleaning, wastewater cleaning and gas engines were installed during 1997-2002, thereafter-commercial operation commenced. The technology has also been transferred to a plant in Yamagata in Japan, which began operation in 2007. Since then two mor e Japanese plants haveClient Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 38 of 52

been added to the list.Case -4 : Lahti Fos ter-Wheel erDevelopin g Lahden Lämpäpövoima OyCompanies/ Institutions Atmospheric CFBOwner Heat and power to the local community, auxiliary system tothe conventional boilerGasification Technology Comm erci alPrimary PurposeTechnology Status 60 MW th inputPower Throughput Kymijärvi Power Plant, Lahti, FinlandLocation The FW CFB gasification technology was developed in the early 1980s, the driver forBrief Description development being very high oil prices. The first commercial-scale CFB gasifiers, using 17 to 35 MW of dry waste wood as feedstock, were delivered for the pulp and paper industry in the mid 1980s, enabling oil to be substituted in the lime kiln process. During the 1990s, a gasification process producing raw gas from a variety of biomass and recycled fuels to be co-combusted in a pulverized coal (PC) boiler was developed. Additionally, three commercial scale atmospheric CFB/bubbling fluidized- bed (BFB) gasifiers with fuel inputs from 40 to 70MW were supplied during the years 1997-2003. In 1997-1998, a 60 MW th atmospheric Foster Wheeler CFB biomass gasifier was installed at the 200 MW th fossil fuel fired Kymijärvi power station, without any significant commissioning problems. The product gas is used in the boiler and the gasifier is flexible when it comes to type of fuel and with an availability of >95%.Case -5 : Nexterra Nexterra Systems Corp. (Vancouver, Canada)Developin gCompanies/ Institutions va ri esOwner Updraft fixed bed gasifierGasification TechnologyPrimary Purpose Heat and PowerTechnology Status Comm erci alPower Throughput 30 MWth or 10 MWel (for cogeneration) outputLocation Several plants in North America, including Oak Ridge (Tennessee,USA), VancouverBrief Description (British Columbia), Columbia(North Carolina, USA), Prince George (British Columbia), Victoria (British Columbia), New W estminster (British Columbia),Heffley Creek Plywood Mill near Kamloops (British Columbia), in Canada if not otherwise stated Nexterra develop, manufacture and deliver advanced gasification systems that enable customers to self-generate heat and power at industrial and institutional facilities using waste fuels. The technology is claimed to be based on a new generation of gasification technology suitable for “inside-the-fenc e” ther mal and cogeneration applications. Nexterra has proven gasification solutions available for the for est industry, institutional (e.g. universities, hospitals, government facilities) and power generation where locally sourced wood waste can be found. Futur e applications include systems that operate on coal and other low cost fuelsCase -6 : TRI Steam Refor merDevelopin g TRI (Ther moChem Recovery International, Inc.)Companies/ InstitutionsClient Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 39 of 52

Owner TRI (licenses parts of the technology from MTCI)Gasification Technology Indirect bubbling fluidized bed gasifier with steam reformer followed by partialPrimary Purpose oxidation of char – customizable H2/COratioTechnology Status Production of biofuels, bio-chemicals, power, heat, steamPower ThroughputLocation Commercial operation of black liquor gasifier and further development of biomass gasification in pilotBrief Description ~20 MWth black liquor (100 tpd) Commercial plant in Ontario, Canada. Pilot plant at in Durham,NC, USA. Two biomass gasification demonstration plants in final engineering phase to be constructed in Wisconsin, USA (100 and 200 MWth input, respectively) MTCI/ThermoChem are the original developers of the technology and TRI was started with a license from them in 1996. Since then TRI have made many modifications and further development and have integrated the gasifier with a steam reformer, which they called ‘TRI Steam Refor mer’. The Maryland-based (USA) TRI has a commercial black liquor gasification plant running in Ontario, Canada. There is currently research carried out to perform biomass gasification in their pilot plant in North Carolina. Two new biomass gasification plants with a thermal input of ~100 MWth and 200 MWth, respectively are in the final engineering phase. These will be used to gasify dry forest residuals for the production of FT liquids. The current system targets 250-2000 tpd of feed but there are plans to develop the technology for the 5-250 tpd range as well. More trials using other feedstock will increase the flexibility of the system.Case -7 : Värö Götaverken, Tampella, Kvaerner, Metso PowerDevelopin g Metso PowerCompanies/ Institutions Atmospheric circulating fluid bedOwner Generation of syngas to be burned in the lime kilnGasification Technology Commercial operationPrimary Purpose 35 MWth inputTechnology Status Södra Cell Värö Pulp Mill, SwedenPower Throughput The Värö gasifier was installed in 1987 at the Södra Cell Pulp Mill In southwesternLocation Sweden.It was designed by Götaverken in Göteborg, who had experience fromBrief Description atmospheric CFB gasification. Due to low oil prices during the early 1990’s, the gasifier was not operating. Tampella Power and Vattenfall founded the company Enviropower in 1992, which was later bought by Metso Power. New development began in 2002, with the primary purposes to supply heat to the limekiln and generate power. Waste gasification, fuel drying and new technologies for gas cleaning were/are also tested. The gasifier now has a role in the lime cycle of the pulping process and has over 90 000 hours of operating timeClient Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 40 of 52

5.3 Annex-3: Standards & CodesA. Mechanical Pakistan Standards International StandardsBl owers ISO 5389; ISO 1217Boil er PS 2383-1989 ISO 1129:1980Compr es s ors PS 2482-1-1989/ 2482-2-1989/ ISO 3857-2:1977 2482-3-1989Condens er PS 1326-1974 ASTM A214 / A214M - 96(2012)Conveyors PS 2377-1989 ISO/TC 41/SC 3Cooling tower *BS 4485 ISO 16345:2014Crane PS 4430-1999 ISO 4301-1Fans PS 663-1987 ISO 5801:2007Heat exchangers PS 3386-2-1993 ISO 1129:1980Gear box PS 4084-1998 ISO/TC 60High pressure valves & fittings PS 1008-1974/ 558-1992/911- ASTM A961 / A961M - 15; ASTM A694 1991 / A694M - 16Low pressure valves & fittings PS 1008-1974/ 558-1992/911- ASTM A961 / A961M - 15; ASTM A694 1992 / A694M - 16Pressure vessels PS 3386-2-1993 ISO 16528-1:2007Pumps PS # 2433-1989 ISO 5199:2002; ISO 9905:1994Turbi ne PS 893-1987 ISO 14661:2000/ IEC-34/ ASME PTC-6SSiesmic considerations PS 4642-3-2000 ISO/DIS 3010Wind load PS 4427-1999 ISO/FDIS 4302B. Electricals & instrumentsCurrent transformer PS 826-2000 IEC 60044DC Battery PS 434-1964 IEC 62133Ea rthi ng PS 4083-1998 IEEE 80Gen era tor PS 1666-1985 IEC 34HV Cables PS 1176-1989HV switchgears PS 2109-1989 IEC 298Illumination systems PS 2111(845)-1989 IEC 61547Lightning protection PS 1046-1974 IEC 61024LV Busduct *IS 8623 IEC 61439LV Cables *IS 1554 IEC 60055LV switchgears PS 1300-1974 IEC 60439/IEC 61915Motors PS 186-1987 IEC 60034-30-1:2014Potential transformer PS 1602-1983 IEC 60076Power transformers PS 563-1-1996 IEC 76Protection relay PS 307-1963 IEC 55UPS PS 2899-5-1991 IEC 146Electrical instruments, drives PS #1666-1985 IEC 61922/IEC 61800,gen era torElectrical instruments, control PS #4158-1998, PS #2199-1989 IEC 60546s ys temsC. MOC for piping *SA335 Gr P22 ASTM A106/A106M>500 oC *SA 335 Gr P11400 to 485 oC *SA 106 Gr B ASTM A320/A320M< 400 oC PS 911-1991 ASTM A 234 ANSI B 16.9/ B 16.28/ BPipe fittings 16.11Client Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 41 of 52

5.4 Annex-4: Manufacturing quality standard5.4.1 Gasifier Reactor• Reactor wall thickness should be calculated as per good engineering practices and considering internal pressure / vacuum of 1000 WC. Minimum thickness should be 5 mm• The manufacturer should specify minimum corrosion allowance• Reactor should be designed and manufactured as per attached data sheet• All nozzle connections on the shell should be made seamless• Use of cast-iron for any pressure part or any part attached to the reactor shell by welding is prohibited• All plates should be manufactured by open hearth, electric furnace or basic oxygen process should adhere to mentioned in PS equivalent, E250 at its minimum• For components inside the reactor, suitable MOC should be selected based on the service temperature• Suitable device / door / seal should be provided to ensure against fire, explosion• A suitable grate / system in the bottom should be provided for periodical removal of ash without disturbing the process• Adequate access for cleaning and maintenance of refractory should be provided• Man-hole cover should be provided with a davit or hinge• Adequate number of peep-holes should be provided for process observation and temperature estimation as long as it does not affect the safety in operations• Lifting lugs should be designed and located in such a manner that no part of the reactor gets over-stressed during transportation & erection. Height of the reactor from ground should provide for convenient disposal of ash and wastewater. Minimum clearance below the reactor or any auxiliary equipment where peopl e movement is envisaged should be 2.2 meters.• Material to be used should conform to: a) ASME Section 11 b) PS equivalent grade• Minimum quality acceptable should be: (Reference for these recommendations) a) Plates: PS equivalent b) Forgings: SA-105 c) PS equivalent tested & inspected as per SA-181 or SA-105 d) Nozzle pipes: SA-106, PS equivalent e) Fittings: SA-234, SA-420 f) Elbow should be long radius type g) Bolting: SA-193 Gr.B7, SA-194 Gr.2H5.4.2 Piping and terminalsMaterial of constructionGas Piping : SS SeamlessAir/Water Piping : CSERWClient Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 42 of 52

Corrosion allowanceUnless otherwise specified in purchaser’s piping material specification, the following corrosionallowance should be provided as a minimum parameter in all the process and utility systems:Carbon Steel : 3.0 mmFerritic Alloys : 3.0 mmAustenitic steel : NILNon-Ferrous : NILDesign temperatureMinimum and maximum design temperatures should be determined in accordance with the provisionsof ANSI B31.3 and in no case should be less severe than those specified.Design pressureThe design pressure of piping should be determined in accordance with the provisions of ANSI B31.3 andin no case should be less than the following: a) 3.5 kg/cm2 b) Design pressure of the equipment to which the piping is connected. c) Set pressure of safety valve, which protects the system. d) For piping at the discharge of centrifugal pump, it should be higher than • 1. 2 times the maximum pump differential pressure plus the maximum suction pressure • Total shut off pressure plus the maximum suction pressure e) Design pressure for piping systems operating under vacuum should be full vacuumCriteria for piping supportsAll piping should be adequately anchored, guided or supported to prevent undue deflection /expansion, vibration or loads on connected equipment & piping and leakage at joints. Piping atequipment such as heat exchangers and pumps, and valves requiring periodic maintenance should besupported in such a way that the equipment and valves could be removed, with a minimum necessityof installing temporary pipe support.Suitable supports should be provided for lines, which do not need any support, but otherwisebecome unsupported by opening of flange, etc. for maintenance; and thus may transfer load onattached equipment, etc. • Threaded connections are not acceptable • Suitable vents & drains should be providedTesting requirements- Non-Destructives Testing (NDT) requirements• Depending on the severity of application, extent of NDT should be decided. As a rule, all alloy steel, hydrogen, oxygen, NACE, and any other high pressure and lethal service should have 100% radiography on weld joints. Castings used in these services should have 50% radiography/ultrasonic.• All piping should be hydro tested at 1.5 x design pressure.Client Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 43 of 52

5.4.3 Allowable movement and loads • Reactor process nozzle/terminals should be designed to accept moments & forces or the movement from external piping/ducting • Piping should be designed as per prevalent standard engineering practices for such applications5.4.4 Refractory and insulation• The temperature of outside casing should not exceed 82°C at an ambient temperature of 27°C in still air• All parts of refractory should be designed to allow for proper expansion of all parts. Where multilayer or multi component linings are used, joints should not be continuous through the lining• Any layer of refractory should be suitable for a service temperature of 167°C above its calculated hot face temperature• Maximum temperature for anchor tips should be as per the specification given in the table belowTable 13: Maximum temperature of anchor tipsAnchor Material Maximum Anchor Temperature °F °C 427Carbon Steel 800 760TP 304 stainless steel 1400 760TP 316 stainless steel 1400 815TP 309 stainless steel 1500 927TP 310 stainless steel 1700 1038RA 330 stainless steel 1900 1093Alloy 601 2000 >1093Ceramic studs and washers >20005.4.5 Brick and tile construction• Brick construction could be used for gravity walls, floors, or as hot-face layers• Gravity walls should be of mortared construction. The mortar should be non-slagging, air-setting, and chemically compatible with adjacent refractory, including the rated temperature of the brick• Gravity walls should be of mortared construction. The mortar shall be non-slagging, air-setting, and chemically compatible with adjacent refractory, including the rated temperature of the brick• Minimum service temperature for a hot face brick layer should be at least 10% more than the inside design temperature• Brick linings should be supported by metal support shelves (lintels) attached to the casing on vertical centers not to exceed 6 feet (1.8 meters). Support shelves should be slotted to provide for differential thermal expansion. Shelf material will be defined by the calculated service temperature; carbon steel is satisfactory up to 700°F (317°C).• Expansion joints should be provided in both vertical and horizontal directions of the walls, at wall edges, and about burner tiles, doors and sleeved penetrations.5.4.6 Castable construction• Hydraulic-setting castables are suitable as lining for all parts of fired heaters. Minimum castableClient Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 44 of 52

construction is a 1:2:4 volumetric mix of Lumnite-Haydite-Vermiculite, limited to a maximum service temperature rating of 1038°C (1900°F) and clean fuel applications. This castable should be limited to 8-inch (20.3 cm) maximum thickness on arches and walls.• For dual layer castable construction, the hot face layer should be minimum 3 inches (7.6 cm) thick. The anchoring systems should provide independent support for each layer when in arch or other overhead position.• Anchoring penetration should not be less than 70 percent of the individual layer being anchored for castable thickness greater than 2 inches (5 cm). The anchor should not be closer than ½ inch (1.3 cm) from the hot face.• The anchoring spacing should be maximum three times the total lining thickness but should not exceed 12 inches (30 cm) on a square pattern for walls and 9 inches (23 cm) on a square pattern for arches. The anchor orientation should be varied to avoid creating continuous shear planes.• Anchors for total castable thickness up to 6 inches (15.2 cm) should be minimum of 3/16 inch (4.8 mm) diameter. Greater refractory thicknesses require a minimum of ¼ inch (6.3 mm) diameter anchors.• Castable linings in header boxes, breechings, and lined flue gas ducts and stacks should not be less than 2 inches (5 cm) thick.• Anchors in 2-inch (5 cm) thick castable linings should be held in place by 10 gauge minimum, carbon steel chain-link fencing, wire mesh, or linear anchors welded to the steel casing.• When metallic fibre is added for reinforcement, it should only be used in castables of 880 kg/m3 (55 lbs./cft.) or greater density. Metallic fibres shall be limited to not more than 3% by weight of the dry mixture.• Low iron content (maximum of 1.5%) materials should be used when total heavy metal content within fuels exceeds 100 parts per million.• Hydraulic setting castables, in particular lightweight and medium weight insulating castables, are susceptible to the development of alkaline hydrolysis (carbonization) when placed under high ambient temperatures and/or high humidity conditions shortly after placement.• To reduce the tendency for hydraulic setting castables to develop alkaline hydrolysis, an application of an impervious organic coating should be applied immediately after castable placement and reapplication of the same coating shortly after the twenty-four (24) hour cure.• The use of forced drying by air movement or low temperature to remove a percentage of the mechanical water prior to the application of the impervious coating could further reduce the possibility of development of alkaline hydrolysis. Alkaline hydrolysis is a natural occurring phenomenon such that the use of either or both of the above procedures may not entirely prevent the formation thereof.• In instances where alkaline hydrolysis has occurred, the loss in refractory thickness is usually less than 10 mm (3/8 inch). When this occurs, the loose material should be brushed off and an impervious organic coating applied.5.4.7 Structure and AppurtenancesStructures • Structural steel should be designed to permit lateral and vertical expansion of heater parts.Client Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 45 of 52

• Gasifier casing plate should be seal welded externally to prevent air and water infiltration. • When fireproofing is specified, the main structural columns from the base to the floor level plus the main floor beams should allow for 3 hours fire resistance and/or 2 inches (50mm) of fireproofing. • Duct structural systems should support ductwork independent of expansion joints during operation, when idle or with duct sections removed.Ladders, platforms, and stairways • Platforms should be provided as follows: o At fuel feeding point o At nozzles having any operating control o At nozzles having local indicators o At any other maintenance requirements • Gasifier reactor with shell diameters greater than 3 meters (10 feet) should have a full circular platform at the floor level. Individual ladders and platforms to each observation door may be used when shell diameters are 3 meters (10 feet or less). • Platforms should have a minimum clear width as follows: o Operating platforms, 900 mm (3 feet) o Maintenance platforms, 900 mm (3 feet) o Walkways, 750 mm (2 feet, 6 inches) • Platform should be designed for 5KN/m2 live load. • Platform decking should be 6 mm (l/4 inch) checkered plate or 25 mm by 5 mm (1 inch by 3/16 inch) open grating. Stair treads should be open grating with checkered plate nosing. • Dual access should be provided to each operating platform except when the individual platform length is less than 6 meters (20 feet). • An intermediate landing should be provided when the vertical rise exceeds 9 meters (30 feet) for ladders and 4.5 meters (15 feet) for stairways. • Ladders should be caged from a point 2.3 meters (7 feet, 6 inches) above grade or any platform. • A self–closing safety gate should be provided for all ladders serving platforms and landings. • Stairways should have a minimum width of 750 mm (2 feet, 6 inches), a minimum tread width of 240 mm (9l/2 inches), and a maximum riser of 200 mm (8 inches). The slope of the stairway should not exceed a 9 (vertical) to 12 (horizontal) ratio. • Headroom over platforms, walkways, and stairways should be a minimum of 2.1 meters (7 feet). • Handrails should be provided on all platforms, walkways, and stairways. • Handrails, ladders, and platforms should be arranged so as not to interfere with any item removal. • Where interference exists, removable sections should be provided.Materials • Materials used in the fabrication of gasifier should conform to the following specifications or purchaser’s approved equivalent specifications:Client Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 46 of 52

o Structural shapes, ASTM A 36, A 242, A 572, PS equivalent o Plate, ASTM A 36, A 283 Grade C, A 242, or A 572, PS equivalent. A o Structural bolts, ASTM A 307, unfinished or equivalent. o High-strength bolts, ASTM A 325 or ASTM A 490 or equivalent. o Pipe for columns and davits, ASTM A 53 Grade B or equivalent. • Materials for service at design ambient temperatures below -30°C (-20°F) should be as specified by the purchaser.Flare stack • Flare stack shall be governed by Central & State pollution control boards • Stack design shall be as per PS (latest edition)5.4.8 ElectricalElectrical equipment viz., motors, junction boxes, instruments should conform torequirement of area classification to be identified as per the requirement of API-500 or PS standardfor classification of hazardous area.5.4.9 Gas cooling & cleaningThe extent of dust removal requirement depends on the final use of gas, i.e. whether (a) as fuel forgas engine or (b) for generating process heat, i.e. burnt gas coming in contact with product or (c) forgenerating utility heat.Gas coolingHeat exchangers should be designed as per applicable codes and standards whenever cooling with heatexchangers is envisaged.Gas cleaningGas cleaning may be achieved in the following manner: • Combined gas de-dusting and gas cleaning by suitable scrubber columns • Separate gas de-dusting and gas cleaning by means of a preliminary hot/warm filtration for particle separation with subsequent gas cleaning of tarry compounds. • Dry gas cleaning: Dry gas cleaning can be hot gas cleaning with heat-resisting filters and into dry gas cleaning in fabric filters, depending upon the temperatures. • The cleaning steps in the hot gas cleaning process can be the following: o Cyclone - primary de-dusting (prior to gas cooling) o Hot gas filter - fine de-dusting (prior to gas cooling) o Bag filter system - fine de-dusting (after gas cooling) o Other filters (sand bed filter, active coke bed) • Wet gas cleaning: Wet gas cleaning is purification by liquid scrubbing agents in a suitable scrubber system and this additionally cools the gas. • Tar treatment systems are used to reduce the tar from producer gas and may be of the following types depending upon the end usage of producer gas. • Fixed bed absorbers, thermal tar treatment, Catalytic tar treatment systems, Wet Scrubbers, ESPs, etc.Client Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 47 of 52

• Dust treatment systems used to remove the dust in producer gases may be Dust ESPs, Filtration de-duster, etc. • Water and air pollutants generated from the gasifier plant should be treated to meet the pollution control requirements5.4.10 Instrumentation and controlUnder the current economic conditions, a biomass gasifier plant needs to be fully automated, allowingfor unmanned operation. Full automation has the advantage that safety procedures can be included inthe system. Any plant needs an automation and control system. However, for small-scale systems, theinstrumentation and control system may become relatively expensive. The following items are mostlyautomated: • Fuel feeding (rotational speed controllers, or opening of valves); • Fuel level in the gasifier reactor; • Oxygen supply to the gasifier reactor (linked to the fuel feeding); • Cleaning sequence of filters (dependent on pressure drop); • Air-gas ratio to the gas engineFollowing table describes the instrumentation and auxiliary connections required:Table 14: Instrumentation and auxiliary connectionsS. No. Item Function1 Thermocouple with Hot gas temperature measurement and high temperature warning Digital display and signal controller Cooled gas temperature measurement Circulating water temperature measurement Biomass drier temperature measurement and control2 Manometers Pressure measurements across each equipment3 Pressure transducers Pressure measurements at critical points for process with digital output control(optional if specified by purchaser)4 Biomass Level sensors To maintain the biomass level in the reactor (optional if specified by purchaser)5 Load Cells/Weighing To maintain the char extraction scales To record biomass loading6 Flow Meters For gas flow measurements For water flow measurements7 Oxygen Monitor To measure level of Oxygen in producer gas8 Gas Analyzer Gas composition measurement (optional if specified by purchaser)9 Flue Gas Analyzer Measure engine exhaust (optional if specified by purchaser)10 CO monitor To measure CO levels at work area (personal safety)11 Moisture meter Biomass moisture controlClient Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 48 of 52

5.5 Annex-5: Good engineering practices 18Good engineering practice related to process is the responsibility of the manufacturer.5.5.1 Choice of material • Reactor vessels, valves and piping material should be constructed from good quality materials • Heat resistant stainless steel or other appropriate material shall be chosen for the gasifier and gas cooling device • Chemical resistant stainless steels recommended for gas scrubbing and washing media circulation5.5.2 Gas tightnessGas tightness is important to avoid gas escape and air intake, which may lead to the formation ofexplosive mixtures and/or the release of toxic gas. The following engineering practices are suitable toensure gas tightness. • The use of welded connections is preferred above flanges, in particular for hot pipes above 500°C. In all cases, proper flange sealing like chemical and thermal resistant material need to be used. • All pipes, aggregates, measurements, devices have to be of proper materials • Proper material should be used with regard to chemical resistance, temperature and pressures corrosion, particle size.5.5.3 Valves • All air inlets to the gasifier and gas outlets the same, including fuel feeding section, flare and engine should be equipped with block devices or anti-back firing valves in series (after the other • in the same line) • When valves are in contact with pyrolysis or gasification gas, they may get stuck • Valves used to ensure a safe mode in case of failure and emergency stop must be of the fail- • safe type Valves at air pipes, filters and cylinders should have position micro switches Faulty settings of manual valves should not be possible. Malfunction of critical valves should be detected5.5.4 Electrical devices • It is recommended to electrically ground all gas conduction parts • PLC should be properly grounded in order to avoid malfunction and accidents • Galvanic separation of electrical supply of measurements devices is strongly recommended • It is recommended to supply PLCs with uninterrupted power supply units(UPS) • Duplicate plant key operation measurement points (critical temperatures, pressures, etc.) are recommended for monitoring using a secondary measurement system during emergency case • or in failure of the main PLC system Gasifier inlet into engine should be earth grounded, and shielded cables should be used to18“Final guideline for safe and eco-friendly biomass gasification” European standardClient Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 49 of 52

avoid electrical break downs that would cause back firing in the inlet system5.5.5 Control and safety devices • CO detectors, giving indication and alarm at about 25/50 ppm CO, must be installed in rooms • with equipment containing pyrolysis or gasification gas • • Pressure and temperature sensors included in the safety concept should be duplicated or tripled. • • The failure probability regarding the influence of operation/ installations must have been • estimated. Heat exchangers between gas and air from a possible hazard source in case of leaks between the media e.g., thermal cracks or corrosion. Similarly, for expansion joints in long welded pipes. Hazards from this possible malfunctioning should be avoided by well-designed equipment and by temperature and oxygen sensors downstream to be able to detect the leakages It should not be possible to tamper safety related leakages. All alarm values should be specified in the manual before start-up of the plant Temperature sensors should be installed before and after the main plant reactor system components. Preferred and allowable operation temperatures shall be available for the operators in plant manuals and secured with proper alarm levels5.5.6 Movable or rotating parts • The plant movable parts, such as conveyor belts, motors, engines could generate a risk of gas explosions. They should be shielded and equipped with visible signs and emergency stop • At standby, the gas blowers and other rotating equipment in the product gas-line should be maintained, otherwise it may corrode or seize through the condensation of tar, which will lead to breakdown5.5.7 Hot surfaces • The plant can have several hot surfaces. These could generate a risk of gas or dust explosion and present a risk of accidental contact with operators. The plant equipment • that can pose an occupational risk due to high temperatures should be adequately identified • and protected (shielded)to reduce risks Training should be provided to educate operators regarding the hazards related to hot surfaces and the use of personal protective equipment (e.g. gloves, insulated clothing, etc.)5.5.8 Gas flaring systems • The flare or a similar device for burning the gas is used when the gas quality is poor and cannot be used in the gas engine, or in case of engine failure • In case where valves in contact with pyrolysis or gasification gas stuck, the gas should • automatically be flared • Gasifier will have to vent gases as they purge pipe-work from the gasifier to the engine. At Start- up, the gasses they purge pipe-work from the gasifier to the engine The flare should be equipped with o An automatic ignition systemClient Name UNIDO DESL Project No. 9A0000005647Project Name Policy advisory services in Biomass gasification technology in Pakistan Version 3 (Final)Report Title Minimum Quality Standards for Biomass Gasification Plants Page 50 of 52