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<p>This study presents the design, modelling, simulation, and experimental validation of a compact pyro-gasifier system developed for the trigeneration of syngas, bio-oil, and biochar using granulated coconut shell biomass as the feedstock. The integrated approach combines MATLAB-based 3D temperature modelling, Aspen Plus process simulation, and hardware prototype testing to bridge the gap between computational analysis and practical performance. The MATLAB simulation of thermal distribution within the dual-chamber reactor revealed effective heat transfer from the gasification to the pyrolysis zone, ensuring uniform decomposition and controlled volatile release. The radial and axial heat conduction profiles, reaching up to 800&#xa0;°C, confirmed stable thermal gradients essential for efficient biomass conversion. Aspen Plus simulations predicted significant energy yields with an enthalpy efficiency of 38.67%, hydrogen enrichment from 9.5% to 49.6%, and a heat recovery potential of 14.47&#xa0;kW from non-condensable gases. The prototype unit, fabricated using recycled metallic components, demonstrated steady operational stability and produced distinct outputs—high-quality bio-oil characterized by dominant O–H and C = O peaks (FTIR) and porous biochar structures confirmed by SEM–EDS analyses. The results affirm that the developed pyro-gasifier ensures efficient thermochemical conversion with reduced CO₂ emissions, minimal tar formation, and high carbon recovery through dual biochar generation. The study establishes a validated, scalable framework for decentralized bioenergy generation, integrating numerical, process, and experimental domains. The proposed system demonstrates technical feasibility, economic viability, and sustainability for advancing circular bioeconomy practices using abundant coconut shell biomass.</p>

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Design and Development of a Compact Pyro-Gasifier System for Bio-Oil and Biochar Production Using Coconut Shell Biomass

  • 期刊论文

  • 发表日期：

    2026年1月12日

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  • K. Ashwini,
  • R. Resmi,
  • Muneer Parayangat,
  • Mohamed Abbas

摘要

This study presents the design, modelling, simulation, and experimental validation of a compact pyro-gasifier system developed for the trigeneration of syngas, bio-oil, and biochar using granulated coconut shell biomass as the feedstock. The integrated approach combines MATLAB-based 3D temperature modelling, Aspen Plus process simulation, and hardware prototype testing to bridge the gap between computational analysis and practical performance. The MATLAB simulation of thermal distribution within the dual-chamber reactor revealed effective heat transfer from the gasification to the pyrolysis zone, ensuring uniform decomposition and controlled volatile release. The radial and axial heat conduction profiles, reaching up to 800 °C, confirmed stable thermal gradients essential for efficient biomass conversion. Aspen Plus simulations predicted significant energy yields with an enthalpy efficiency of 38.67%, hydrogen enrichment from 9.5% to 49.6%, and a heat recovery potential of 14.47 kW from non-condensable gases. The prototype unit, fabricated using recycled metallic components, demonstrated steady operational stability and produced distinct outputs—high-quality bio-oil characterized by dominant O–H and C = O peaks (FTIR) and porous biochar structures confirmed by SEM–EDS analyses. The results affirm that the developed pyro-gasifier ensures efficient thermochemical conversion with reduced CO₂ emissions, minimal tar formation, and high carbon recovery through dual biochar generation. The study establishes a validated, scalable framework for decentralized bioenergy generation, integrating numerical, process, and experimental domains. The proposed system demonstrates technical feasibility, economic viability, and sustainability for advancing circular bioeconomy practices using abundant coconut shell biomass.