Verification, Testing and Optimisation of Low-density Biomass and Agricultural Waste on a Commercial Gasifier Using Empirical Data and First-principal Analysis

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Independent third-party testing and verification were conducted at a gasification facility in northwestern Türkiye to evaluate the performance of an updraft dual-zone gasifier operating on a low-density biomass blend consisting of 66.7% forest residue and 33.3% tea waste. Key operating parameters, including thermal oil temperatures, flow rate, ORC power output, gasifier vacuum, syngas temperature, and internal zone temperatures, were recorded at 3–5-minute intervals. As direct measurements of feedstock and syngas flow rates were unavailable, a mass and energy balance approach was applied using measured thermal oil energy, an assumed boiler efficiency of 85%, constant syngas composition, and a feed-to-char ratio derived from fixed carbon content. Gas chromatography analysis indicated a syngas composition of CH4 4.7%, CO2 11.2%, H2 17.5%, N2 42.1%, O2 1.1%, and CO 23.3%, corresponding to a calorific value of 6.52 MJ/m³. The analysis yielded a cold gas efficiency of 66.74%, hot gas efficiency of 71.74%, and an overall efficiency of 97.14% when accounting for char energy. Carbon conversion efficiency was calculated at 80.75%. Biochar characterization confirmed high carbon stability (H:C 0.37) and a Class 4 carbon storage classification. The study demonstrates the application of first-principles engineering combined with empirical data to evaluate commercial gasification systems.