Ok Started design work on the next generation Flex Series gasifier plant. Now that I have most of the manufacturing process complete for the the Utility Series product line I can be done with that. This will be the first time in our existence that an entire product line has these support systems in place. So we will be able to fly on those builds in the future. The Evolution S 3 and 4 units are most likely going to get dropped this yeas. The new Evolution S1 and S2 units will make them obsolete as these machines can be stacked in multiple units to achieve up to 100 kW outputs. To achieve 25 kW you can simply stack two of the smaller units together with less cost. These smaller versions are more practical in operation as they only make power on demand, have full automatic run modes, with run times of 10 hours each pr hopper load with a smaller hopper. The waveform is also a pure sign and they have grid tie capability right out of the box. Replacement parts are much more cost effective as well. Replacing a small V Twin vs a high output V8 big difference there. I can only estimate efficiencies at this point, however, with the automatic mode fuel is never wasted, the machine will never sit and idle are run for stand by. It will shut down on its own and save that fuel for when its needed. Taking an educated guess the smaller versions I think have around 3 X the efficiency as the larger machines.
So this brings me to a position to start new development. This was supposed to happen last year, but our work load was just to much to take this on. What will be different for this years development we actually get to keep this one, We will have a space for this thing to live in the shop and we will be performing advanced testing so we can get actual numbers on efficiencies. We will have current builds to test against as we go.
So the new Flex R2S1 will be the most advanced gasifier system we have ever created. All of its concepts have had proof of concept but not all have been implemented into one machine. With all combined they will work with each other and are needed to support each process each brings.
The Flex R1S2 should be thought of as a charcoal gasifier system that produces its on char. Its has two reactors an upper and a lower. The upper reactor is no longer the primary gas producer, its primary job now is to create char for the lower reactor. This where some other added processes are in order to aid the upper reactor The HGRS system we experimented with before will be a shared system. This system purges out the hopper gas and processes this using engine exhaust heat. Not only is this gas combustible but will carry high temp steam via the exhaust reclaim. To aid the upper reactor it is then reinjected into the upper portion of the upper primary hearth/reactor. This will add into drying process and also produce additional pyrolysis gas as it reduces fuels at this stage. This additional gas produced will build up and some of it will enter down stream through the gasifier adding steam reforming processes. The rest will continue in the HGRS loop. The inert gas input will be much less with this added process.
The lower reactor is built sort of like an updraft imbert. We need to keep the oxidation zones relatively shallow for size constraints. A small portion of the gas from the HGRS is used to control temps at the jets. Additionally a center jet is added to inject the processed hopper gases into the center where the oxidation zones merge. The lower unit will should result in very minimal char yield, so ash clean out servicing should be greatly extended possibly weeks. In theory this system alone should add an additional 20% efficiency gain the gasifeir system and over all gas density should increase substantially.
Other added features to this build are the automatic ignition ports for both reactors and additional ports intake ports are added to support the full automation systems. I am also roughing out the regen Micron filter system and this will be built along side this machine. This filter should scrub the gas clean to where tar issues are completely eliminated along with soots.