Performance and emission analysis of an integrated cross-draft biomass gasifier and cyclonic burner with an air-mixing chamber for hot air generation in wood drying for international export

Abstract

This study evaluates the performance of an integrated cross-draft gasifier and cyclonic burner (ICGB) equipped with a cyclone air-mixing chamber, developed to generate hot air for industrial pallet manufacturing. The assessment includes biomass utilization efficiency, thermal performance, pollutant emissions, economic benefits, and compliance with international standards. Three lumber sizes were dried for pallet assembly, followed by additional heat treatment to meet IPPC–ISPM 15 certification requirements. Results show that the ICGB system significantly enhanced energy efficiency and operational performance, achieving a high thermal efficiency of 94.2 %. Fuel consumption decreased by 60.1 % for Lumber-A (83 × 102 mm), 65.1 % for Lumber-B (38 × 102 mm), and 70.9 % for Lumber-C (16 × 102 mm), corresponding to cost savings of up to 268 EUR per drying cycle (70 %). Drying times were reduced from 168 to 96 h (43 %) for Lumber-A, 120 to 60 h (50 %) for Lumber-B, and 48 to 20 h (58 %) for Lumber-C, while assembled pallets required 50 % less time. Emissions remained within regulatory limits, with CO = 419–428 mg Nm⁻³ (< 1,108), NO<inf>x</inf> = 469–477 mg Nm⁻³ (< 528), and SPM = 187–190 mg m⁻³ (< 320), while CO<inf>2</inf>-equivalent emissions decreased by 71 %. These improvements reduce fuel use, emissions, and energy consumption, leading to lower production costs and higher throughput while ensuring compliance with export standards. The ICGB-based drying room thus offers a cost-effective, energy-efficient, and environmentally sustainable alternative to conventional systems, though further techno-economic and payback analyses are recommended for large-scale applications.