APL News 

Gasifier Kits

GEKIV_v5_2-2012_GEKIV_v5_2-2012_IMG_3241Rev Judy GEK IV

The Gasifier Experimenters Kit makes it easy for beginners and experts alike to run high performance experiments in small scale gasification and pyrolysis. Whether you’re a DIY enthusiast, commercial user, or university researcher; the GEK will get you over the starting hurdles and onto the more rewarding work of making clean gas for experiments inpower generation, or biochar for soil amendment.

The GEK is designed in a modular fashion for easy switch out between common reactor types and operating situations. You can use the GEK to run an expertly configured downdraft gasifier for testing the viability of various feedstocks for use in biomass-fired power generators such as the Power Pallet. Or you can use the same system to create a multi-mode pyrolysis reactor for biochar making and soil studies.

The result is a uniquely powerful “LEGO system” of biomass thermal conversion. The GEK lets you deploy all the commonly discussed, but rarely implemented, “expert solutions”– and does so at the smaller-scale and lesser price needed for personal scale energy experiment project.

Build it or Buy it

You decide the relative amount of effort vs cost you want to invest towards your finished GEK. You can “build-the-GEK-from-scratch” using our FREE open source CAD files. Unfortunately, we can not provide technical support for DIY projects based on the CAD files. Don’t want a fab project? You can also buy the GEK fully fabricated and ready for final assembly and firing on your end.

Every GEK kit includes the reactor, hopper, cyclone and filter vessels, as well as every plumbing part, nut, and bolt needed to finish the job. Instrumentation is included too, which will help guide you to successful operation of your unit. You will need to provide an external source of suction, usually an air compressor capable of moving 8-10 water column inches. Please note: since these air compressors require significant amounts of electricity, the GEK and GEK TOTTI kits are not suited for off-grid operation, nor for power generation outside small scale experiments.

Whichever route you choose, our goal is to provide the best new engineering solutions in gasification and pyrolysis, open and honest information, and the physical equipment to make it all happen at uniquely value optimized prices.

 

Basic Reactor

The default reactor for the GEK is an Imbert type downdraft reactor.  An Imbert is the usual starting point for generating low tar wood gas to power internal combustion engines. The GEK Imbert is delivered with a default configuration known to produce clean syngas when operated by a knowledgeable operator, using appropriate fuels.

The standard 3″ hearth and nozzle configuration will run 5-20hp engines, or 3kw to 12kw of electrical load.  Switching to the optional 4″ hearth expands gas rates to support engines up to 40hp, or a 20-25kw genset.   You can run many different types of engines and gensets with either configuration.  See here for the pros and cons of various GEK-engine-genset combinations. Again, however, please note that the GEK is for experimental purposed. For power generation, please choose the Power Pallet.

The GEK Imbert combines all common Imbert internal variations into a single reconfigurable reactor.  It elaborates these basics with significant improvements to the traditional design.  Improvements include:

  • Robust air preheating system, raises air to 600-700C before the nozzles
  • Stainless steel construction
  • Multi-layer kaowool batt insulation
  • Monorator condensing hopper
  • Improved cyclone and filter particulate separation
  • Variable air nozzle position and size
  • Exchangeable hearth size and type

See the GEK Gallery for pictures and videos of these features in action.

gektotti_IMG_3135REVweb_v2

 

Add-ons and Customizations

GEK IV

The modular design of the GEK lets you add important performance parts and process elaborations to the basic kit. The most important of these is the Hot TOTTI (Tower of Total Thermal Integration) – a total heat recovery and recirculation solution.

The full Hot TOTTI system results in higher combustion and cracking temperatures for improved tar conversion, increased tolerance for high moisture fuels, and increased gasifier efficiency. Putting these waste heats back into the reactor also eliminates the need for a radiator at the end of the system to dump otherwise useful heat. The Hot TOTTI is a combination of Auger Feed Drying Bucket and Pyrocoil IC exhaust gas heat exchanger. The Auger Feed Drying Bucket uses output wood gas to dry your incoming fuel, while at the same time cooling the outgoing gas. The PyroCoil heat exchanger returns heat from the engine exhaust back into the reactor, further eliminating drying loads as well as most of the pyrolysis load.

The Hot TOTTI innovations are the main reason the GEK can deliver unusually good performance on regular wood chip fuel, with up to 30% moisture content– and do so in a compact and minimized form factor. See here for more detailed info on the Hot TOTTI.

GEKTOTTI-AllVesselsDimensionStudy4-2.vc6


Performance Particulars: Satisfaction Guaranteed or 100% Money Back

The basic GEK is not a turnkey wood gasification unit. Given the variability of fuels and human operators, we cannot guarantee perfection right out of the box. However, in the hands of a knowledgeable operator, many have proved the GEK will produce excellent results.

Success is also very accessible to the beginner, but know it will require your active participation and learning. Of course we are here to help you with this, which is the point of the GEK collaboration. We also help at the outset by including free instrumentation with every kit. This makes it possible to use our ”speedometer” and “tachometer” operating instructions to keep things in the good gas making range, not shoot in the dark on best guesses.

We believe the design, open source collaboration and manufacturing particulars of the GEK are a powerful value proposition. If you buy a GEK and find the particulars to be otherwise, you can return the unit for a 100% money back refund. After more than 250 units delivered and no requests for refunds after actual use, this is an easy promise for us to make.

The Basic GEK® Kit

The Basic GEK® kit includes all the components needed for a full gasification system. Don’t be fooled that the reactor is the main issue and all the other components are minor details. A complete wood gas generator is as much a filtering, cooling, vac/blower, gas distribution and burner system as it is the core gas making reactor.

The GEK kit gives you all needed vessels, accessories and details -down to the last nut and bolt- to get you up, running, and producing engine grade gas. Every kit includes the following:

  • stainless steel reactor and gas cowling
  • innovative air preheating system
  • multi-layer ceramic wool insulation
  • grate shaker and ash handling system
  • fuel hopper with monorator condenser
  • cyclone particulate separator
  • large packed bed filter with foam secondary filtration
  • ejector-venturi gas pump
  • fuel/air mixer and swirl burner for clean flaring
  • taper inserts to prevent fuel bridging
  • “puff lids” for safety relief
  • high temp gas plumbing
  • ceramic and silicone gaskets
  • all needed nuts, bolts, and hardware.

Instruments are also included with every kit so you can use our ”speedometer” and “tachometer” operating instructions and keep your GEK in the good gas making range. See here for more specs on the basic GEK downdraft reactor.


GEK LEVEL IV:


(Currently, GEK TOTTI’s can be produced and shipped within 30-45 days after receipt of payment)

GEK® TOTTI™ 20kW Full Fabricated, Ready to Assemble (stainless steel) $5,835

 

*July 28, 2014:NOTE- NOT CURRENTLY FOR SALE*  We have temporarily suspended sales of the GEK, due to differences in design of the GEK versus the Version 5.0 Power Pallet, and our desire to only sell our best most advanced work. If you are interested in one, please EMAIL us at sales@allpowerlabs.org and we will contact you when they are again available.

gektotti_IMG_3135REVweb_v2

gektotti_IMG_2906REVweb_v2gektotti_IMG_2960REVweb

 

 

 

GEK® TOTTI™

GEK IV

The modular design of the GEK lets you add important performance parts and process elaborations to the basic kit. The most important of these is the Hot TOTTI (Tower of Total Thermal Integration) – a total heat recovery and recirculation solution that solves many of the problems with the historic Imbert.

The Hot TOTTI is a combination of Auger Feed Drying Bucket and Pyrocoil IC exhaust gas heat exchanger. The Auger Feed Drying Bucket uses output wood gas to dry your incoming fuel, while at the same time cooling the outgoing gas. The PyroCoil heat exchanger returns heat from the engine exhaust back into the reactor, further eliminating drying loads as well as most of the pyrolysis load.

The result is higher combustion and cracking temperatures for improved tar conversion, increased tolerance for high moisture fuels, and increased gasifier efficiency. Putting these waste heat streams back into the reactor also eliminates the need for a radiator at the end of the system to dump otherwise useful heat.

The Hot TOTTI innovations are the main reason the GEK can deliver unusually good performance on regular wood chip fuel, with up to 30% moisture content– and do so in a compact and minimized form factor. See here for more detailed info on the Hot TOTTI.

20kW GEK® TOTTI™ Includes Level IV GEK plus Auger Feed Drying Bucket & Pyrocoil (stainless steel reactor and gas cowling, not pictured) $5,835

*July 28, 2014:NOTE- NOT CURRENTLY FOR SALE*  We have temporarily suspended sales of the GEK, due to differences in design of the GEK versus the Version 5.0 Power Pallet, and our desire to only sell our best most advanced work. If you are interested in one, please EMAIL us at sales@allpowerlabs.org and we will contact you when they are again available.


The finer print on GEK kits and add-on parts To place your order by phone, call 510-845-1500 or toll free 888-252-5324 during the hours of 10 AM and 6 PM Pacific Standard Time. We’ll be happy to answer any questions you may have before you order.

Orders can be placed using the “buy now” buttons above, or via check to: ALL Power Labs 1010 Murray Street Berkeley, CA 94710 If you would like to pay by wire transfer, or need a formal invoice, please use our contact form and state which version of the GEK you would like to purchas. All prices are freight on board, Berkeley, CA, 94710. California sales tax of 8.75% applies to all orders within California. 

Shipping: all kits nest into their hopper and filter for easy and inexpensive UPS shipping. Domestic shipping is via UPS ground. Write us and we can quote specifics. International shipping is via UPS/DHL air freight, with a 7-10 day delivery. Shipments to Canada are sent via regular UPS ground. GEK units can also be picked up at the shop in Berkeley, California by appointment. Our shipping terms are CIP unless otherwise stated in writing. The GEK TOTTI kits weigh approximately 300 lbs. Questions? Contact us here.