Finite Element Analysis of Structural Integrity and Fatigue Life of Char Removal System in High-Temperature Gasification

Nina K. Supriatna; Agung T. Kuncoro; Bayu A. Saputro; Muhammad  Iksanudin; Silviana Simbolon; Muhammad Yunus; Prima Zuldian; Agus Kismanto; Maulana Arifin; Raden I. Purawiardi

doi:10.33116/ije.v9i2.364

Authors

Nina K. Supriatna Research Center for Energy Conversion Technology, Badan Riset dan Inovasi Nasional
Agung T. Kuncoro Department of Mechanical Engineering, Universitas Pamulang
Bayu A. Saputro Department of Automotive and Mechanical Engineering, Universitas Muhammadiyah Magelang
Muhammad Iksanudin Department of Mechanical Engineering, Universitas Gajah Mada
Silviana Simbolon Department of Mechanical Engineering, Universitas Pamulang
Muhammad Yunus Research Center for Nuclear Reactor Technology, Badan Riset dan Inovasi Nasional
Prima Zuldian Research Center for Energy Conversion Technology, Badan Riset dan Inovasi Nasional
Agus Kismanto Research Center for Fuel Technology, Badan Riset dan Inovasi Nasional
Maulana Arifin Research Center for Energy Conversion Technology, Badan Riset dan Inovasi Nasional
Raden I. Purawiardi Research Center for Energy Conversion Technology, Badan Riset dan Inovasi Nasional

DOI:

https://doi.org/10.33116/ije.v9i2.364

Keywords:

Biomass gasification, finite element analysis, fatigue life, structural integrity, char removal

Abstract

Biomass gasification is a crucial technology for sustainable energy conversion; however, its continuous operation and overall efficiency are heavily dependent on the reliable extraction of solid by-products. This study investigates the structural integrity and fatigue life of a char removal system used in high-temperature biomass gasification. The system operates under severe thermo-mechanical conditions, including elevated temperatures and varying mechanical loads, which may lead to structural degradation and failure. A Finite Element Analysis (FEA) approach using ANSYS was employed to evaluate the performance of ASTM A36 steel under mechanical loads of 100 kg, 150 kg, and 200 kg, combined with thermal conditions of 800 °C, 1000 °C, and 1200 °C. Key parameters analyzed include equivalent stress, elastic strain, total deformation, safety factor, and fatigue life. The results indicate that while temperature variations have minimal influence on peak stress values, they significantly affect the distribution of strain and deformation due to material stiffness degradation. In contrast, mechanical loading has a dominant impact on structural performance, leading to increased stress, deformation, and reduced safety factors. Fatigue analysis reveals that while the structure maintains a theoretical infinite design life of 1 × 10? cycles across all loads, the minimum fatigue safety factor drops significantly from 2.92 at 100 kg to 1.46 at 200 kg. In conclusion, ASTM A36 steel is structurally adequate and can safely withstand the applied thermo-mechanical loads without premature fatigue failure. However, the reduced safety margins under elevated mechanical loads highlight the critical need for load control and targeted geometric reinforcements at structural joints to ensure long-term reliability. To ensure long-term reliability and operational safety in biomass gasification systems, it is imperative to implement targeted geometric reinforcements at connection points or substitute the standard carbon steel with high-temperature-resistant alloys.

Downloads

Download data is not yet available.

References

Agrawal, A. P., Ali, S., Kumar, V., & Gupta, P. (2025). Investigating the impact of heat treatment on mechanical behaviour of A36 low-carbon steel. Archives of Thermodynamics, 141–149. https://doi.org/10.24425/ather.2025.156586

Al-Mukhtar, A., & Koenke, C. (2025). Fatigue life analysis of cruciform specimens under biaxial loading using the Paris equation. Metals, 15(6), 579. https://doi.org/10.3390/met15060579

Alshoaibi, A. M., & Ali Fageehi, Y. (2022). 3D modelling of fatigue crack growth and life predictions using ANSYS. Ain Shams Engineering Journal, 13(4), 101636. https://doi.org/10.1016/j.asej.2021.11.005

Alshoaibi, A. M., Ghazwani, M. A., & Hakami, M. H. (2021) . Fatigue life and reliability assessment of metal structures. Engineering Solid Mechanics, 9, 13–22. https://doi.org/10.5267/j.esm.2020.7.001

Ates, F., & Tezcan Un, U. (2013). Production of char from hornbeam sawdust and its performance evaluation in the dye removal. Journal of Analytical and Applied Pyrolysis, 103, 159–166. https://doi.org/10.1016/j.jaap.2013.01.021

Barrionuevo, G. O., Guerrero, B. A., & Walczak, M. (2020). Computational fracture mechanics: evaluation of the structural integrity in a penstock applying the BS7910 standard and finite element analysis. IOP Conference Series: Materials Science and Engineering, 925(1). https://doi.org/10.1088/1757-899X/925/1/012023

Beber, V. C., & Schneider, B. (2020). Fatigue of structural adhesives under stress concentrations: Notch effect on fatigue strength, crack initiation and damage evolution. International Journal of Fatigue, 140, 105824. https://doi.org/10.1016/j.ijfatigue.2020.105824

Bhowmik, M., Banerjee, P., & Bhowmik, M. K. (2020). A theoretical study of thermal stress for engineering applications. In Applications and techniques for experimental stress analysis (pp. 176–201). IGI Global https://doi.org/10.4018/978-1-7998-1690-4.ch012

Cao, B., Zhao, Y., Yang, T., & Liu, C. T. (2021). L12?strengthened Co?rich alloys for high?temperature structural applications: a critical review. Advanced Engineering Materials, 23(10). https://doi.org/10.1002/adem.202100453

Das, O., Sarmah, A. K., & Bhattacharyya, D. (2015). Structure-mechanics property relationship of waste derived biochars. Science of the Total Environment, 538, 611–620. https://doi.org/10.1016/j.scitotenv.2015.08.073

Fu, Y.-F., Gong, J., Li, P.-W., & Yang, Z.-M. (2017). Fatigue life assessment of screw blades in screw sand washing machine under extreme load. American Journal of Mechanical Engineering, 5(1), 1–7. https://doi.org/10.12691/ajme-5-1-1

Lestari, P., Surjosatyo, A., Dafiqurrohman, H., Saputro, B. A., Dhani, S. T., & Nami, H. (2025). Optimization of syngas production and biochar utilization from municipal solid waste (MSW) via integrated pyrolysis-gasification for electricity generation. Bioresource Technology Reports, 31, 102217. https://doi.org/10.1016/j.biteb.2025.102217

Munson, K., Kihm, F., & Halfpenny, A. (2017). Improving the accuracy of dynamic vibration fatigue simulation. SAE International Journal of Engines, 10(2), 2017-01–0333. https://doi.org/10.4271/2017-01-0333

Nikulin, S. A., Rogachev, S. O., Nikolaev, Y. A., Vasiliev, S. G., Belov, V. A., & Turilina, V. Y. (2021). High-temperature mechanical properties of low-carbon steel used for the manufacture of core catcher vessel. Progress in Nuclear Energy, 142, 104015. https://doi.org/10.1016/j.pnucene.2021.104015

Nwigbo, S. C., & Nwoye, C. F. (2015). Thermal and residual stress analysis on A36 steel plate brazed with a known volume of Zn50 brazing alloy (filler metal). Journal of Failure Analysis and Prevention, 15(6), 924–931. https://doi.org/10.1007/s11668-015-0037-2

Sadasivam, S., Zagorš?ak, R., Thomas, H. R., Kapusta, K., & Sta?czyk, K. (2020). Experimental study of methane-oriented gasification of semi-anthracite and bituminous coals using oxygen and steam in the context of underground coal gasification (UCG): Effects of pressure, temperature, gasification reactant supply rates and coal rank. Fuel, 268, 117330. https://doi.org/10.1016/j.fuel.2020.117330

Saputro, B. A., Surjosatyo, A., Sari, W. R., Dafiqurrohman, H., Qossam, I. Al, & Lestari, P. (2025). Hydrogen-rich syngas production of solid waste supercritical water gasification multi-objective process optimization. International Journal of Renewable Energy Development, 14(4), 629–645. https://doi.org/10.61435/ijred.2025.60848

Sun, Y., Song, D., Sun, S., & Liu, Y. (2024). Study on fatigue performance and topology optimization of cast steel bifurcation joint under alternating load. Engineering Research Express, 6(4), 045107. https://doi.org/10.1088/2631-8695/ad84a1

Supriatna, N. K., Zuldian, P., Aminuddin, Purawiardi, I., Aprianti, N., Gunawan, Y., Fariza, O., Raksodewanto, A. A., Alamsyah, R., Hasanuzzaman, M., & Surjosatyo, A. (2024). Experimental investigation and performance evaluation of Samanea saman leaves and twigs gasification from urban residential garden waste as alternative future energy. Bioresource Technology Reports, 27, 101950. https://doi.org/10.1016/j.biteb.2024.101950

Supriatna, N. K., Zuldian, P., Gunawan, Y., Aprianti, N., Aminuddin, Nurjanah, N., Umi Culsum, N. T., Purawiardi, R. I., Prasetya, A., Tjahjono, E. W., Alamsyah, R., & Surjosatyo, A. (2025). Kinetic and thermodynamic analysis of garden waste gasification for clean syngas production. Thermal Science and Engineering Progress, 68, 104239. https://doi.org/https://doi.org/10.1016/j.tsep.2025.104239

Yang, S. I., Chung, I. L., & Wu, S. R. (2012). An experimental study of the influence of temperature on char separation in a moving granular bed. Powder Technology, 228, 121–127. https://doi.org/10.1016/j.powtec.2012.05.006

Zeng, X., Ueki, Y., Yoshiie, R., Naruse, I., Wang, F., Han, Z., & Xu, G. (2020). Recent progress in tar removal by char and the applications: A comprehensive analysis. Carbon Resources Conversion, 3, 1–18. https://doi.org/10.1016/j.crcon.2019.12.001

Zhu, B. J., Wang, T., & Zhang, L. X. (2018). Mechanical Behavior of Assembled Steel Dampers with Optimized Shapes. Key Engineering Materials, 763, 959–966. https://doi.org/10.4028/www.scientific.net/KEM.763.959