Rapidox 5100 Syngas Analyser Boosts Energy Conversion Efficiency for Microwave Plasma Gasification‑Fuel Cell Coupling Project

Company Profile

Founded in 1982, Stopford Limited is a European engineering consulting and technology R&D enterprise focused on low‑carbon and environmental protection sectors. Although not a large‑scale industrial conglomerate, it possesses in‑depth technical know‑how in the cutting‑edge niche of microwave plasma gasification. The company has independently developed the Plasmergy microwave‑induced plasma gasification process, dedicated to the resource and energy‑oriented utilisation of medical waste and various solid wastes. It has delivered multiple demonstration projects backed by the UK government and enjoys high recognition within Europe’s solid‑waste innovation community.

In the field of solid‑waste recycling and waste‑to‑energy power generation, Microwave‑Induced Plasma (MIP) gasification has become a state‑of‑the‑art energy conversion route thanks to its capacity for treating diverse waste materials. Stopford has launched an innovative project that integrates its proprietary Plasmergy microwave plasma gasification process with Solid Oxide Fuel Cells (SOFC). Compared with conventional gas engine solutions, the project aims to achieve a substantial leap in power‑generation efficiency.

Gasification technology converts carbon‑containing solid feedstocks such as biomass, waste and solid recovered fuel into syngas (primarily hydrogen and carbon monoxide) under oxygen‑deficient conditions at temperatures above 700 °C. The resulting syngas can be further used for heat and power production. However, syngas from gasification features dynamically fluctuating composition and carries multiple contaminants including hydrogen sulphide, hydrogen chloride, tar, particulate matter and alkali metals. Direct feeding of such syngas into solid oxide fuel cells will impair cell service life and the operational stability of the whole system.

Two key challenges must be overcome to realise efficient coordination between gasification units and SOFC fuel cells: optimising the chemical composition of syngas and effective removal of impurity contaminants. Real‑time online monitoring of syngas composition and contaminants is therefore a critical link for process development and commissioning.

To satisfy monitoring requirements for process commissioning, Stopford selected the Cambridge Sensotec Rapidox 5100 Syngas Analyser, complete with a full set of gas pre‑treatment accessories: PTFE particulate filter, carbon‑capture filter and bubbling filter unit.

Rapidox 5100 Syngas AnalyserParticulate PTFE & carbon‑capture filter kitLarge wet water‑filled bubbling filter chamber

The complete system serves two major functions:

1. Gas pre‑treatment unit: Removes impurities including tar, dust and acid gases by filtration, protecting both the analyser and downstream fuel cells.

2. Rapidox 5100 Analyser: Performs real‑time measurement of syngas composition supplied to fuel cells. When plasma gasification process parameters are adjusted, syngas constituents and system efficiency will change accordingly. The instrument outputs fast real‑time data to support iterative process optimisation.

Dr Michael Wilkinson, Chief Technical Specialist at Stopford, commented: “Equipped with matching pre‑treatment components, the Rapidox 5100 provides an online monitoring solution enabling fast access to real‑time operational syngas data.”

Dr Ben Herbert, Director of Technology & Innovation at Stopford, stated: “The full Rapidox 5100 system has played a vital role in the development of Plasmergy technology, and the technical service delivered by Cambridge Sensotec is also excellent.”

Targeting solid‑waste disposal scenarios such as medical waste treatment, this project validates the application value of syngas analysers for the innovative plasma gasification‑fuel‑cell coupling process. It offers a proven monitoring solution for process optimisation and system commissioning of waste‑to‑energy gasification projects.