Practical Hand Book of Gas, Oil and Steam Engines / Stationary, Marine, Traction; Gas Burners, Oil Burners, Etc.; Farm, Traction, Automobile, Locomotive; A simple, practical and comprehensive book on the construction, operation and repair of all kinds of engines. Dealing with the various parts in detail and the various types of engines and also the use of different kinds of fuel.

by John B. Rathbun

(12) Producer Gas.

Producer gas which is generated by the incomplete combustion of fuels in a deep bed is the most commonly used gas for engines having a capacity of 50 horsepower and over, because of the simplicity and economy of its production. While producer gas has been obtained from practically every solid fuel, of which coal, coke, wood, lignite, peat, and charcoal are examples, the fuel most generally used is either coal or coke. While producer gas is much lower in calorific value than either natural or illuminating gas it gives admirable results in the gas engine and is a much cheaper fuel than coal gas in units above 50 horse-power capacity. The fuel is completely burned to ash in the producer without the intermediate coke product that exists in the manufacture of coke.

A producer consists of three independent elements as shown by Fig. F-6; the PRODUCER or generator (A), the steam boiler (B), and the SCRUBBER or purifier (C). The incandescent fuel (F) in the form of a cone lies on the grate bars (G) at the lower end of the producer. Above the burning fuel is a deep bed of coal (D) which reaches to the top of the producer at which point it is admitted to the bed through the charging valve or gate (H). The gas resulting from the combustion in the producer is drawn out of the tank through the gas outlet pipe (E) by the suction of the engine. The air for the combustion is drawn up through an opening in the ash pit (J) by the engine.

When the oxygen of the air strikes the incandescent fuel on the grate it combines with a portion of it forming carbon dioxide (CO₂) which is an incombustible gas, but on passing through the burning fuel above this point, one atom of the oxygen in the CO₂ recombines with the fuel forming the combustible gas—carbon monoxide (CO). Because of the distilling effect of the heat in the bed, the volatile hydrocarbons of the coal are set free and mingle with the CO formed by the combustion. The producer gas consists, therefore, principally of CO, with a certain proportion of the volatile hydrocarbons of the coal such as marsh gas, ethylene, and some oil vapor.

Since the hydrocarbons are easily condensed on coming into contact with the coal walls of the piping, to form trouble making tars and oils, they must either be washed out of the gas in the purifier or passed again through the high temperature zone to convert them into permanent gases. In the usual producer, the hydrocarbons are reheated, as they form a considerable percentage of the heat of the gas. After the volatile constituents are reheated, the gases pass through the boiler (B), which absorbs the heat of the gas in generating steam, and from this point the gases enter the scrubber where the dust and the residual tars are removed. The scrubber, which is a sort of filter, is an important factor in the generating plant, for if the dust and dirt were allowed to pass into the cylinder of the engine it would only be a question of a short time until the valves and cylinder would be ground to pieces.

When the steam from the boiler is allowed to flow into the ash pit of the producer and up through the incandescent fuel, the heat separates the water vapor into its two elements, oxygen and hydrogen. The oxygen set free combines with the carbon in the coal forming more carbon monoxide, while the hydrogen which is unaffected by the combustion adds to the heat value of the gas. The last additions to the combustion due to the disassociation of the steam are really what is known as “water gas.” A limited amount of steam may be admitted continuously in this manner without lowering the temperature of the fuel below the gasifying point, and its presence is beneficial for it not only provides more CO and hydrogen but produces it without introducing atmospheric nitrogen. The steam is also a great aid in preventing the formation of clinkers on the grate bars. Since the air used in burning the fuel in the first reaction contains about 79 per cent of nitrogen, which is an inert gas, the producer gas is greatly diluted by this unavoidable admixture, which accounts for its low calorific value.

Fig. F-6. Diagram of Suction Gas Producer Showing the Generator, Boiler and Washer.

While the air required for the combustion of the fuel is drawn through the producer by the suction of the engine in the example shown (SUCTION PRODUCER), there is a type in common use called a PRESSURE PRODUCER in which the air is supplied under pressure to the ash pit by a small blower, which causes a continuous flow of gas above atmospheric pressure.

Gas producers are divided into two classes: suction producers and pressure producers. The suction producer presents the following advantages:

1. The pipe line is always less than atmospheric pressure, hence no leaks of gas to the air are possible.

2. The regulation of the gas supply is automatic.

3. No gas storage tank is required.

4. The production of gas begins and stops with the engine.

5. Uniform quality of gas.

The suction producer is limited to power application and cannot be used where the gas is to be used for heating, as in furnaces, ovens, etc., or where the engine is at a distance from the producer, unless pumped to its destination.

The pressure producer does not yield a uniform quality of gas, hence requires a storage tank where low quality gas will blend with gas of higher calorific values and produce a gas of fairly uniform quality.

The pressure producer is adapted to the use of all grades of fuels, such as bituminous coal and lignite.

Anthracite coal contains little volatile matter and is an ideal fuel for the manufacture of producer gas, while bituminous coal with its high percentage of volatile matter and tar, requires more efficient scrubbing, as these substances must be removed from the gas.

On starting the producer shown by Fig. 6, the producer is filled with the proper amount of kindling and coal, and a blast of air is sent into the ash pit by a small blower, the products of combustion being sent through the by-pass stack (K) until the escaping gas becomes of the quality required for the operation of the engine. The by-pass valve is now closed, and the gas is forced through the scrubber to the engine until the entire system is filled with gas. When good gas appears at the engine test cock the engine is started, and the blower stopped, the gas now being circulated by the engine piston. The volume of gas generated by the producer is always equal to that required by the engine so that no gas receiver or reservoir is required. Because of the friction of the gas in passing through the fuel, scrubber and piping, its pressure at the engine is always considerably below that of the atmosphere, which of course reduces the amount of charge taken into the cylinder. Because of the weak gas and the low pressure in the piping, it is necessary to carry a much higher compression with producer gas than with natural or illuminating gas.

The efficiency of a producer is from 75 to 85 per cent, that is, the producer will furnish gas that has a calorific value of an average of 80 per cent of the calorific value of the fuel from which it is made, the remaining 15 to 20 per cent being consumed in performing the combustion. This is far above the efficiency of the furnace in a steam boiler, as an almost theoretically exact amount of air can be supplied in the producer to effect the combustion, while in the boiler furnace about ten times the theoretical amount is passed through the fuel bed to burn it. Heating up this enormous volume of air to the temperature of the products of combustion consumes a large amount of fuel and reduces the efficiency of the furnace considerably. Because of the reduction in the air supply, a gas fired furnace is always more efficient than one fired with coal. Producer gas with 300,000 British thermal units per thousand cubic feet, and oil having 130,000 British thermal units per gallon will result in 1,000 cubic feet of gas being equal to about 2.30 gallons of fuel oil.

If the gas is to be used for heating ovens or furnaces in connection with the generation of power, the character of the fuel will be determined to a great extent by the requirements of the ovens and by the type of producer used, as each fuel will give the gas certain properties. Thus gas used for firing crockery will not be suitable for use in open hearth steel furnaces, as the impurities in the various fuels may have an injurious effect on the manufactured product. The cost of the fuel, cost of transportation, heat value, purity, and ease of handling are all factors in the selection of a fuel.

The size and condition of a fuel is also of importance. Exceedingly large lumps and fine dust are both objectionable.

Wet fuel reduces the efficiency of the producer, as the water must be evaporated, this causing a serious heat loss.

With careful attention a producer gas engine will develop a horse-power hour on from 1 to 1¼ pounds of anthracite pea coal, and in many instances the consumption has been less than this figure. The efficiency in dropping from full load to half load varies by little, one test showing a consumption of 1.1 pounds of coal per horse-power hour at full load and 1.6 pounds of coal at half load. Producer gas power is nearly as cheap as water power, in fact the producer gas engine has displaced at least two water plants to the writer’s knowledge. According to an estimate made by a well known authority, Mr. Bingham, it is possible for a producer gas engine to generate power for only .1 of one cent more per K.W. hour than it is generated at Niagara Falls.

According to the United States Bureau of Mines,

“The tests in the gas producer have shown that many fuels of so low grade as to be practically valueless for steaming purposes, such as slack coal, bone coal and lignite, may be economically converted into producer gas and may thus generate sufficient power to render them of high commercial value.

“It is estimated that on an average each coal tested in the producer-gas plant developed two and one-half times the power that it would develop in the ordinary steam-boiler plant.

“It was found that the low-grade lignite of North Dakota developed as much power when converted into producer gas as did the best West Virginia bituminous coals burned under the steam boiler.

“Investigations into the waste of coal in mining have shown that it probably aggregates 250,000,000 to 300,000,000 tons yearly, of which at least one-half might be saved. It has been demonstrated that the low-grade coals, high in sulphur and ash, now left underground, can be used economically in the gas producer for the ultimate production of power, heat and light, and should, therefore, be mined at the same time as the high-grade coal.

“As a smoke preventer, the gas producer is one of the most efficient devices on the market, and furthermore, it reduces the fuel consumption not 10 to 15 per cent, as claimed for the ordinary smoke preventing device offered for use in steam plants, but 50 to 60 per cent.”