ALL POWER LABS

personal scale power

ALL Power Labs

ALL Power Labs is the global leader in small-scale gasification. We make biomass gasifiers that are ready for everyday use and serve real world distributed energy needs. Our project began in 2008 with the open source Gasifier Experimenters Kits (GEK) for research and education. It has since evolved into the Power Pallet - a fully automated solution for biomass power generation. Today you can find over 400 of our systems, in over 40 countries, supporting research in over 50 universities.

INDEX
Power PalletTM Use Cases, Benefits & ROI Research Equipment & Instrumentation Authorized Representatives & ALL Power Labs Page 4-9 Page 10-11 Page 12-13 Page 14-15

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Electricity From Biomass

Power Pallet

TM

The Full Solution

The Power Pallet is a complete biomass power generation solution that converts woody biomass to electricity, heat, or PTO shaft power. It is a compact and fully automated system delivered at the breakthrough price of $1 to $2 per watt. Power Pallets are available in 10 kW and 20 kW sizes using Kubota and GM industrial engines, paired with Mecc Alte AVR generators. The resulting combination delivers stable electricity from biomass at 120/208/240 VAC, 60 Hz or 50 Hz, in single, split, or three phase.

Why Its Different

The Power Pallet is distinguished by its ease of use, compact size, and affordable price. It is a solution that delivers the hands-off operation expected from modern power generation equipment. These advantages are the result of breakthroughs in electronic control and waste heat recycling. An onboard microcontroller provides the expertise usually required from a trained operator. A multi-stage gasication architecture, combined with an innovative gasifier-engine thermal integration, significantly improves tar conversion and fuel flexibility. The result is a compact and technically advanced gasification solution that is practical for everyday use.

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Power Pallet Features

TM

The Power Pallet consists of a multi-stage gasifier, spark fired industrial engine, generator head, and Process Control Unit (PCU). The PCU monitors and responds to all internal reactor, engine, and filter conditions, displaying the results on an LCD screen. The PCU also automatically adjusts the syngas/air mixture via a wide band Bosch oxygen sensor and shakes the ash grate when required by reactor conditions.

Hopper: Steel hopper holds up to 10 hours of fuel. Flare: Premixed swirl burner ensures clean start-up. TOTTI: Waste heat recovery and recirculation system for improved tar cracking and moist fuel tolerance. Gas Filter: Packed bed filter with washable foam elements. GEK Gasifier: Compact multi-stage downdraft gasifier system that produces clean gas Skid Base: All components come mounted to a forliftready skid.

PCU: Automated control system, oxygen sensor, syngas/air adjustment, and ash grate shaker.

Engine: The Power Pallet is powered by: 10kW - Kubota 3-cyl 962cc 20kW - GM 4cyl 3.0L

Genhead: 10kW or 20kW Mecc Alte industrial generator with automatic voltage regulation (AVR). Twelve wire genhead is reconfigurable on-site to 120/208/240 VAC. 50Hz or 60Hz in single, split, or 3-phase.

POWER PALLET SPECS Power Output Biomass Consumption Fuel Moisture Tolerance Dimensions Weight

10 kW
1-10 kW 12 kg / 26 lbs per hour at 10 kW Up to 30% 1.2m x 1.2m x 1.8m 48 x 48 x 72 499 kg / 1100 lbs

20 kW
2-20 kW 22 kg / 50 lbs per hour at 20 kW Up to 30% 1.2m x 1.3m 1.8m 51 x 53 x 72 658 kg / 1450 lbs

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Engines

Biomass
Gasifying 2.5lb (1.2 kg) of biomass produces about 2.5 m 3 of gas which produces about 1.25 HP-hr which produces about 1 kWh
The best fuel for the GEK gasifier is chunky, dry, carbon-dense woody biomass. Fuels such as wood chips, wood chunks, nut shells, and coconut shells ranging in size from 0.5 to 1.5 (10mm to 50mm) are ideal.

10kW
Kubota DG 972
Kubota engines have a well earned reputation for high reliability and extreme longevity in a wide variety of applications. Robust performance and compact footprint have made them the engine of choice for small scale industrial, agricultural, and generator applications. This 962cc 3-cylinder inline gaseous fuel engine is based on the companys acclaimed diesel engines. The new combustion chamber, designed exclusively for the gaseous fuel engine, reduces emissions and the raised compression ratio increases efficiency.

20kW
GM Vortec 3.0 L I-4
The Vortec 3.0 L inline 4-cylinder engine is produced exclusively for industrial and marine applications. It has the longest production history of any GM Powertrain industrial engine, with a well-earned reputation for durability and reliability. The engine comes factory configured for gaseous fuels, with features including: Increased compression ratio Sintered powder metal exhaust valve seat inserts for enhanced durability Nodular iron crankshaft for increased strength and durability

FUEL TYPE Hardwood Chips Softwood Chips Nut Shells Coconut Shell Corn Cobs Coffee Grounds Sawdust Rice Husks Straw Sugar Cane Bagasse Corn Stover Poultry Litter

WILL IT WORK Yes Yes Yes Yes Yes Yes Yes No No No No No

HOW WELL Excellent Excellent Excellent Excellent Excellent Fair Fair

COMMENTS 0.5 to 1.5 (10mm 50mm) chips 0.5 to 1.5 (10mm 50mm) chips Needs least preparation Broken into chunks Broken into chunks Pelletized Pelletized

We do not currently recommend using any of the following fuels with our gasification systems: MSW, tires, medical waste, and coal.

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Use Cases, Benefits and ROI

The Power Pallet provides reliable, low-cost electricity anywhere biomass is available.
Low Cost Electricity Electricity can be generated from biomass for as low as US $0.02 per kWh. Generating power with diesel is dramatically more expensive. The cost of obtaining power with solar or wind is often prohibitively expensive without subsidies.
FUEL PRICE COMPARISON Fuel Diesel Biomass Price Range $0.35 - 0.50 kWh $0.02 - 0.05 kWh

IDEAL USES AND INDUSTRIES

Small Businesses Rural Electrification and Microgrids Cell Towers, Radio Station Operators Food Processors Commercial Refrigeration Agriculture Forestry Off-Grid Homes Pumps, Wells, and Boreholes Hospitals and Clinics Colleges and Universities Energy Research

Low Biomass Demand The Power Pallet is designed at a scale that allows individual users to easily source biomass fuel locally and sustainably. This feature allows for easy operation and management without dependence on large-scale biomass supply chains, thus enabling operation in remote locations and developing countries.
BIOMASS FUEL CONSUMPTION
10 kW Engine (@ 75% load) Biomass Weight 1 Hour 8 Hours 24 Hours 9 kg 72 kg 216 kg Power Output 7.5 kWh 60 kWh 180 kWh 20 kW Engine (@ 75% load) Biomass Weight 18 kg 144 kg 432 kg Power Output 15 kWh 120 kWh 360 kWh

Renewable Clean Energy Biomass gasification is a clean, carbon neutral method of producing electricity. When gasification is coupled with biochar production, the process becomes carbon negative. Biochar is a highly beneficial soil amendment that can sequester carbon for hundreds to thousands of years. Affordable The Power Pallet is one of the most affordable renewable energy systems on the market and delivers attractive ROI without economic subsidies. At just $1 to $2 per watt, the capital cost of our system is much less expensive than comparable solar or wind power systems. Simple to Use and Maintain The Power Pallet is the first system of its kind that makes gasification easy and userfriendly. We provide a range of training videos and manuals to get you up and running quickly. In addition, our systems are easy to service and can be maintained by most engine or generator mechanics.

Note: 1.2 kg biomass is roughly equal to 1 kWh electrical output

Electricity in Remote Areas The Power Pallet uses locally available fuel. Unlike diesel, agricultural and forest wastes are readily available and do not require shipping over long distances.

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Research Equipment
GEK Process Control Unit (PCU)
The PCU is an Arduino-based, open source sensing and control board based on the Atmel AVR ATmega1280 processor. The board is specifically designed for the types of instrumentation and automation requirements of biomass thermal conversion projects. The board offers a generous number of thermocouple, pressure, analog signal, and frequency inputs, and an array of servo driver and high current PWM capable DC N-channel switched outputs. Networking to other devices is supported via USB, serial, SD card, and CANbus (the networking standard for engine systems). The PCU is ideal for applications which require integrated instrumentation, datalogging and control.
FEATURES (V3.02) Processor Thermocouple Inputs High/Low Pressure Inputs ( 28/8 H2O) FET Outputs (5 A continuous) Analog Inputs (10-bit, Phidgets connectors) Frequency/Counter Input R/C Hobby Servo Outputs Display (4x20 Character) 4 Button Keypad MicroSD Slot CANbus Hardware RS-232 Interface Prototype/Expansion Area Atmel ATmega 1280 16 K-type 4/2 8 8 1 3 YES YES YES YES YES YES

Instrumentation
Research Instrumentation Kit
The Research Instrumentation Kit includes all the basic temperature, pressure, flow, and tar testing accessories needed for gasification research and teaching. The following accessories are compatible with data input ports on the PCU.
Tar Testing
Colorimeter to measure tar concentration Pump, filter, and filter holder for gas sampling (100) Filter discs (100) Vials for tar dissolution

Temperature
(6) K-type 24 point probe thermocouples (10) K-type hard probe thermocouples (6, 12, 24) Fittings and bushings for TC mounting

Flow Rate
(2) flow meters (air in, gas out)

Pressure
Barbs and plumbing to connect PCU to tap points

Proportional servo valve to control gasifier flow Silicone tubing rate Silicone tubing, barbs and plumbing

Portable Infrared Gas Analyzers

The Gasboard 3100 (rack mounted) and Gasboard 3100P (portable) infrared gas analyzers can be used to measure the concentration of up to 6 gases such as: CO, CO2, CH4, H2, CnHm, O2, and calculate the caloric value automatically. These analyzers are typically used for gas analysis in biomass or coal gasification, steel production blast furnaces, and coking.

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Authorized Representatives Program

About ALL Power Labs

ALL Power Labs (APL) is the leading manufacturer of equipment for small-scale biomass gasification and a resource for open-source alternative energy solutions. Through GEK workshops hosted around the world, free online fabrication plans for individuals, and affordable ready-to-run systems, APL makes it easy for you to obtain high-performance solutions in small-scale gasification and pyrolysis. The ALL Power Labs team is an unusual combination of DIY fabricators and university-trained scientists and engineers. The result is a powerful combination of technical ability and physical know-how for developing innovative energy solutions.

We believe our personal scale power products are on the cusp of a transformational uptake in the market and on the ground. Waste biomass fuel is nearly everywhere and often free. Rural electrification - whether developing world or otherwise - usually suffers from high cost or high intermittency, with few options that truly replace the usability of the grid or a diesel genset. But its difficult to demonstrate the technology from our base in Berkeley, California. Thats why ALL Power Labs is growing a network of local market partners, or Authorized Representatives, who understand the profound market potential of our technology and want to be a part of our continued growth. To learn more about our Authorized Representative Program, please contact: sales@allpowerlabs.org.

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ALL POWER LABS

1010 Murray Street Berkeley, CA 94710 U.S.A.

Tel: 510-845-1500 Toll Free:888-252-5324 sales@allpowerlabs.org www.gekgasifier.com

The GEK Gasifier was developed and is manufactured by ALL Power Labs in Berkeley, CA. GEK Power Pallet TOTTI and BEK are trademarks of ALL Power Labs. 2012 All rights reserved.