WO2009009891A1 - Gazéifieur comprenant un ou plusieurs conduits de fluide - Google Patents

Gazéifieur comprenant un ou plusieurs conduits de fluide Download PDF

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Publication number
WO2009009891A1
WO2009009891A1 PCT/CA2008/001301 CA2008001301W WO2009009891A1 WO 2009009891 A1 WO2009009891 A1 WO 2009009891A1 CA 2008001301 W CA2008001301 W CA 2008001301W WO 2009009891 A1 WO2009009891 A1 WO 2009009891A1
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WO
WIPO (PCT)
Prior art keywords
gasifier
gas
processing
processing chamber
feedstock
Prior art date
Application number
PCT/CA2008/001301
Other languages
English (en)
Inventor
Andreas Tsangaris
Original Assignee
Plasco Energy Group Inc.
Plascoenergy Ip Holdings, S.L., Bilbao, Schaffhausen Branch
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Plasco Energy Group Inc., Plascoenergy Ip Holdings, S.L., Bilbao, Schaffhausen Branch filed Critical Plasco Energy Group Inc.
Priority to CA2731115A priority Critical patent/CA2731115A1/fr
Priority to US12/669,431 priority patent/US20100154304A1/en
Publication of WO2009009891A1 publication Critical patent/WO2009009891A1/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
    • C10J3/02—Fixed-bed gasification of lump fuel
    • C10J3/20—Apparatus; Plants
    • C10J3/22—Arrangements or dispositions of valves or flues
    • C10J3/24—Arrangements or dispositions of valves or flues to permit flow of gases or vapours other than upwardly through the fuel bed
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G5/00—Incineration of waste; Incinerator constructions; Details, accessories or control therefor
    • F23G5/02—Incineration of waste; Incinerator constructions; Details, accessories or control therefor with pretreatment
    • F23G5/027—Incineration of waste; Incinerator constructions; Details, accessories or control therefor with pretreatment pyrolising or gasifying stage
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G5/00—Incineration of waste; Incinerator constructions; Details, accessories or control therefor
    • F23G5/08—Incineration of waste; Incinerator constructions; Details, accessories or control therefor having supplementary heating
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G5/00—Incineration of waste; Incinerator constructions; Details, accessories or control therefor
    • F23G5/50—Control or safety arrangements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G7/00—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals
    • F23G7/10—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals of field or garden waste or biomasses
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23J—REMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
    • F23J7/00—Arrangement of devices for supplying chemicals to fire
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23L—SUPPLYING AIR OR NON-COMBUSTIBLE LIQUIDS OR GASES TO COMBUSTION APPARATUS IN GENERAL ; VALVES OR DAMPERS SPECIALLY ADAPTED FOR CONTROLLING AIR SUPPLY OR DRAUGHT IN COMBUSTION APPARATUS; INDUCING DRAUGHT IN COMBUSTION APPARATUS; TOPS FOR CHIMNEYS OR VENTILATING SHAFTS; TERMINALS FOR FLUES
    • F23L7/00—Supplying non-combustible liquids or gases, other than air, to the fire, e.g. oxygen, steam
    • F23L7/002—Supplying water
    • F23L7/005—Evaporated water; Steam
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2200/00—Details of gasification apparatus
    • C10J2200/09—Mechanical details of gasifiers not otherwise provided for, e.g. sealing means
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0913—Carbonaceous raw material
    • C10J2300/0916—Biomass
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0913—Carbonaceous raw material
    • C10J2300/0916—Biomass
    • C10J2300/092—Wood, cellulose
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0913—Carbonaceous raw material
    • C10J2300/093—Coal
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0913—Carbonaceous raw material
    • C10J2300/0943—Coke
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0913—Carbonaceous raw material
    • C10J2300/0946—Waste, e.g. MSW, tires, glass, tar sand, peat, paper, lignite, oil shale
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0953—Gasifying agents
    • C10J2300/0956—Air or oxygen enriched air
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0953—Gasifying agents
    • C10J2300/0959—Oxygen
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0953—Gasifying agents
    • C10J2300/0973—Water
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/12—Heating the gasifier
    • C10J2300/123—Heating the gasifier by electromagnetic waves, e.g. microwaves
    • C10J2300/1238—Heating the gasifier by electromagnetic waves, e.g. microwaves by plasma
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/18—Details of the gasification process, e.g. loops, autothermal operation
    • C10J2300/1807—Recycle loops, e.g. gas, solids, heating medium, water
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/18—Details of the gasification process, e.g. loops, autothermal operation
    • C10J2300/1807—Recycle loops, e.g. gas, solids, heating medium, water
    • C10J2300/1823—Recycle loops, e.g. gas, solids, heating medium, water for synthesis gas
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G2201/00—Pretreatment
    • F23G2201/40—Gasification
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G2203/00—Furnace arrangements
    • F23G2203/80—Furnaces with other means for moving the waste through the combustion zone
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E20/00—Combustion technologies with mitigation potential
    • Y02E20/12—Heat utilisation in combustion or incineration of waste

Definitions

  • the invention pertains to the field of gasification, and, in particular, to a gasifier comprising one or more fluid conduits.
  • Gasification is a process that enables the conversion of carbonaceous feedstock, such as municipal solid waste (MSW), biomass or coal, into a combustible product gas.
  • the product gas can be used to generate electricity or as a basic raw material to produce chemicals and liquid fuels.
  • the gasification reaction consists of feeding carbonaceous feedstock into a heated gasifier along with a controlled and/or limited amount of oxygen/air and optionally steam, hi contrast to incineration or combustion, which operates with excess oxygen to produce CO 2 , H 2 O, SOx, and NOx, gasification reactions produce a raw gas composition comprising CO, H 2 , H 2 S, and NH 3 .
  • the primary gasification products of interest are H 2 and CO.
  • Possible uses for the product gas from the gasification reaction include: the combustion in a boiler for the production of steam for internal processing and/or other external purposes, or for the generation of electricity through a steam turbine; the combustion directly in a gas turbine or a gas engine for the production of electricity; fuel cells for the production of electricity and/or steam (heat); the production of methanol and other liquid fuels; as a further feedstock for the production of chemicals such as plastics and fertilisers; the extraction of both hydrogen and carbon monoxide as discrete industrial fuel gases; and other industrial applications.
  • a number of systems have been proposed for capturing heat produced by the gasification reaction and utilising such heat to generate electricity, generally known as combined cycle systems.
  • the energy in the product gas coupled with substantial amounts of recoverable sensible heat produced by the process throughout the gasification system can generally produce sufficient electricity to drive the process, thereby alleviating the expense of local electricity consumption.
  • Useful feedstock can include any municipal waste, waste produced by industrial activity and biomedical waste, sewage sludge, coal, heavy oils, petroleum coke, heavy refinery residuals, refinery wastes, hydrocarbon contaminated soils, biomass, and agricultural wastes, forestry wastes and/or by-products, tires, and other hazardous waste.
  • the volatiles may include H 2 O, H 2 , N 2 , O 2 , CO 2 , CO, CH 4 , H 2 S, NH 3 , C 2 H 6 , unsaturated hydrocarbons such as acetylenes, olefins, aromatics, tars, hydrocarbon liquids (oils) and char (carbon black and ash).
  • the means of accomplishing a gasification reaction vary in many ways, but rely on four key engineering factors: the atmosphere (level of oxygen or air or steam content) in the gasifier; the configuration and dimensions of the gasifier; the internal and external heating means; and the operating temperature for the process.
  • Factors that affect the quality of the product gas include: feedstock composition, preparation and particle size; gasifier heating rate; residence time; material feeding method (dry or slurry feed system), the feedstock-reactant flow arrangement, the design of the dry ash or slag removal system; whether it uses a direct or indirect heat generation and displacement method; and the syngas cleanup system.
  • Gasification is usually carried out at a temperature in the range of about 650 0 C to 1200 0 C, either under vacuum, at atmospheric pressure or at pressures up to about 100 atmospheres.
  • slag As the feedstock is heated, water is the first constituent to evolve. As the temperature of the dry feedstock increases, volatilization takes place. During volatilization, the feedstock is thermally decomposed to release tars and light volatile hydrocarbon gases, with the formation of char, a residual solid consisting of both organic and inorganic materials. At high temperatures (such as above 1200°C), inorganic mineral matter is fused or vitrified to form a molten glass-like substance called slag. The slag is usually found to be non-hazardous and may be disposed of in a landfill as a non-hazardous material, or sold as an ore, road-bed, or other construction material.
  • the gas generated in the gasification reaction comprises a wide variety of volatiles, such as the kind of gas that tends to be generated in a low temperature gasifier with a "low quality" carbonaceous feedstock, it is generally referred to as off-gas. If the characteristics of the feedstock and the conditions in the gasifier generate a gas in which
  • syngas CO and H 2 are the predominant chemical species, the gas is referred to as syngas.
  • the raw gas or the raw syngas is converted to a more refined gas composition in a gas reformulating system (GRS) prior to cooling and cleaning through a gas conditioning system (GCS).
  • GRS gas reformulating system
  • GCS gas conditioning system
  • the object of the invention is to provide a gasifier comprising one or more fluid conduits.
  • a gasifier comprising one or more fluid conduits for converting carbonaceous feedstock into an off- gas and residual solid material, the gasifier comprising a refractory-lined processing chamber having one or more fluid conduits located therein to facilitate the passage of fluid; one or more input(s) for receiving feedstock; one or more residue outlets; and heating means to facilitate the conversion process; and a control system for controlling various aspects of the gasification process; wherein the conduit facilitates the input of process additives and/or the exit of steam and/or off-gases from the processing chamber.
  • the gasifier is configured for recycling steam and/or off-gas and/or recycled heat back into the processing chamber.
  • the gasifier further comprises one or more material displacement control modules for facilitating movement of the reactant material through the gasifier, agitation or mixing means to facilitate mixing of reactant material with process additives.
  • the material displacement control modules and/or the agitation or mixing means is operatively coupled to the control system.
  • a gasifier for conversion of carbonaceous feedstock into off-gas and solid residue comprising a refractory-lined processing chamber comprising one or more fluid passage conduits located therein; one or more additive inputs for input of additives into the processing chamber; one or more gas outputs for output of the off-gas from the processing chamber; one or more feedstock inputs for input of the carbonaceous feedstock into the processing chamber; and one or more residue outputs for output of the solid residue from the processing chamber; wherein the one or more additive inputs and/or the one or more gas outputs is provided via the one or more fluid passage conduits, hi one embodiment of the invention, the gasifier comprises two or more fluid passage conduits.
  • a vertically oriented gasifier for conversion of carbonaceous feedstock into off-gas and solid residue
  • the gasifier comprising a descending bed processing chamber comprising one or more fluid conduits located therein, one or more vertically successive processing regions being distributed within the chambers, within each one of which a respective process selected from the group consisting of drying, volatilization and carbon conversion is at least partially favoured, the processing regions being identified by chemical conditions respectively enabling each of the respective process; one or more material displacement control modules adapted to control a vertically downward movement of the feedstock through the processing regions to enhance each of the at least partially favoured process; one or more additive inputs for input of additives into the one or more processing regions; one or more gas outputs for output of gas from the gasifier; one or more feedstock inputs located near a first of the processing regions; and one or more residue outputs; wherein one or more of the one or more additive inputs and/or the one or more gas outputs is provided via the one
  • a horizontally oriented gasifier for conversion of carbonaceous feedstock into off-gas and solid residue
  • the gasifier comprising a processing chamber comprising one or more fluid conduits located therein, one or more horizontally successive processing regions being distributed within the chambers, within each one of which a respective process selected from the group consisting of drying, volatilization and carbon conversion is at least partially favoured, the processing regions being identified by chemical conditions respectively enabling each of the respective process; one or more material displacement control modules adapted to control a horizontal movement of the feedstock through the processing regions to enhance each of the at least partially favoured process; one or more additive inputs for input of additives into the one or more processing regions; one or more gas outputs for output of gas from the gasifier; one or more feedstock inputs located near a first of the processing regions; and one or more residue outputs; wherein one or more of the one or more additive inputs and/or the one or more gas outputs is provided via the one or more fluid conduits
  • Figure IA is a schematic representation of a vertically oriented gasifier for input of process additives therein, in accordance with one embodiment of the present invention.
  • Figure IB is a schematic representation of a vertically oriented gasifier for output of gas therefrom, in accordance with one embodiment of the present invention.
  • Figure 1C is a schematic representation of a horizontally oriented gasifier for input of process additives therein, in accordance with one embodiment of the present invention.
  • Figure ID is a schematic representation of a horizontally oriented gasifier for output of gas therefrom, in accordance with one embodiment of the present invention.
  • Figure 2 is a representation of the processing regions in a gasifier comprising a single processing chamber, in accordance with one embodiment of the present invention.
  • Figure 3 A is a schematic representation of a vertically oriented gasifier comprising three processing regions and two fluid conduits for output of gas therefrom in different directions, in accordance with one embodiment of the present invention.
  • Figure 3B is a schematic representation of a vertically oriented gasifier comprising three processing regions and two fluid conduits, one of which is configured for input of process additives therein and the other for output of gas therefrom, in accordance with one embodiment of the present invention.
  • Figure 4 shows a schematic of a gasifier employing cross-flow of additives and reactant material.
  • Figures 5 to 8 show different embodiments for extraction of off-gases from the different processing regions using the fluid conduit.
  • Figure 5 A shows the separate extraction of off-gas from the first processing region while the off-gases from the second and third processing regions are combined and extracted at the bottom.
  • Figure 5B shows the separate extraction of off-gases from all three processing regions.
  • Figure 6A shows the separate extraction of off-gas from the second processing region while the off-gases from the first and third processing regions are combined and extracted at the bottom.
  • Figure 6B shows the 3D view of a fluid conduit used for extraction and combination of off-gases from different processing regions, such as shown in the embodiment of Figure 6 A.
  • Figure 7 shows the extraction of gas separately from the different processing regions as well as from opposite directions.
  • Figure 8A shows the extraction of gas separately from the different processing regions as in the same direction.
  • Figure 8B shows the 3D view of a fluid conduit used for separate extraction of off-gases from different processing regions, such as shown in the embodiment of Figure 8 A.
  • Figures 9A-B and 1OA show different embodiments with injection of additives into the processing chamber(s) using the fluid conduit located therein and the extraction of gas using output elements disposed around the processing chamber(s).
  • Figure 9A shows the off-gases from all three processing regions collected in a single jacket and piped to downstream processes
  • Figure 9B shows the off-gases from different processing regions collected in separate jackets and piped to downstream processes.
  • Figure 1OA shows the injection of additives independently into the different processing regions and the off-gases collected in multiple jackets around the gasifier.
  • Figure 1OB shows the internal design of the fluid conduit for independent injection of additives into the different processing regions as shown in the embodiment of Figure 1OA.
  • Figures HA and HB show different schematics for recycling of the gases as additives;
  • Figure HA shows the off-gas from the first processing region extracted using the gas conduit heated and recycled back into the third processing region;
  • Figure 1 IB shows the off-gas from the first processing region extracted using the output elements around the processing chamber, heated and recycled back into the third processing region using the gas conduit.
  • Figures 12A-F show various designs for reduced plugging of holes on the conduits located in the inner volume of the processing chamber used for extraction of gas.
  • Figure 12A uses standard hole in the side of the conduit;
  • Figure 12B uses holes that are partially covered with a hat/cap; and
  • Figure 12C uses holes that are completely covered with a hat/cap.
  • Figures 12D-F show variations in the design of the hole.
  • Figure 13A-C show various designs of the protector (hat/cap) of Figures 12B-C, in accordance with various aspects of the invention.
  • Figures 14A-C show the schematic representations of various gasifiers having three processing regions defined therein and comprising a fluid conduit for output of gas therefrom, in accordance with various embodiments of the present invention.
  • Figure 15A is a schematic representation of a processing chamber cross section, in accordance with one embodiment of the present invention.
  • Figures 15B and 15C are perspective diagrams of different processing chambers having a cross section as illustrated in Figure 15 A.
  • Figure 16A is a schematic representation of a processing chamber cross section, in accordance with another embodiment of the present invention.
  • Figure 16B is a perspective diagram of a processing chamber having a cross section as illustrated in Figure 16A
  • Figure 17A is a cross-sectional schematic of a processing chamber with a rotating arm-based material displacement control module, in accordance with one embodiment of the invention.
  • Figure 17B shows the corresponding top- view of the rotating arm.
  • Figure 18A is a perspective, cut away view of a processing chamber using an extractor screw-based material displacement control module, in accordance with an embodiment of the invention.
  • Figure 18B shows a cross-sectional view of a slight variation of the chamber of Figure 18A where a residue outlet is moved away from the processing chamber to avoid direct drop, in accordance with one embodiment of the present invention.
  • FIGS 19A and 19B show cross-sectional views of two different processing chambers using pusher ram-based material displacement control modules, in accordance with one embodiment of the present invention.
  • Figures 20A-B show the design of a extractor screw to act as a fluid conduit.
  • Figure 2 IA-C show various injection options for the extractor screw configured to also act as a fluid conduit.
  • Figure 22 is a mixing device based on a toothed wheel, in accordance with one embodiment of the invention.
  • Figures 23 A to 23D shows details of different mixing devices based on one or more agitator panels.
  • Figure 23 A shows the front view of a flat panel.
  • Figure 23B shows the side view of a V-shaped panel.
  • Figure 23C shows the side view of the flat panel of Figure 23 A while Figure 23D shows the side view of a sloped panel.
  • FIGs 24A to 24E are top plan representations of the various mixing devices shown in Figure 23, in accordance with different embodiments of the invention, wherein the mixing device comprises one or more agitator panels such as a flat panels/spokes as illustrated in Figure 24A; a V-Shape panel/spokes as illustrated in Figure 24B; an off-set panel/spokes as illustrated in Figure 24C; a rotating panel/spokes as illustrated in Figure 24D; and a sloped panel as illustrated in Figure 24E.
  • the mixing device comprises one or more agitator panels such as a flat panels/spokes as illustrated in Figure 24A; a V-Shape panel/spokes as illustrated in Figure 24B; an off-set panel/spokes as illustrated in Figure 24C; a rotating panel/spokes as illustrated in Figure 24D; and a sloped panel as illustrated in Figure 24E.
  • Figures 25A to 25D are top plan representations of a gasifier comprising one or more mixing devices in accordance with different embodiments of the present invention, wherein the mixing devices comprise a flat panel moving in a circular motion as illustrated in Figure 25A; two flat panels moving in a circular motion as illustrated in Figure 25B; a flat panel moving in a bi-directional circular motion as illustrated in Figure 25C; and multiple rotating agitators as illustrated in Figure 25D.
  • the mixing devices comprise a flat panel moving in a circular motion as illustrated in Figure 25A; two flat panels moving in a circular motion as illustrated in Figure 25B; a flat panel moving in a bi-directional circular motion as illustrated in Figure 25C; and multiple rotating agitators as illustrated in Figure 25D.
  • Figures 26A to 26H show designs for the heat recycling system used in different embodiments of the invention
  • Figure 26 A uses separate additive streams and a cascade of heat exchangers
  • Figure 26B uses separate additive streams and a parallel array of heat exchangers
  • Figure 26C uses a single additive stream and a cascade of heat exchangers
  • Figure 26D uses a single heat exchanger and multiple 'fresh' additive streams
  • Figure 26E uses a cascade of heat exchangers with the reheating of gas from the first processing region
  • Figure 26F uses a cascade of heat exchangers with the gas from the first processing region dehumidified and recycled as water
  • Figure 26G uses a cascade of heat exchangers with one heat exchanger servicing multiple processing regions
  • Figure 26H shows the embodiment of 26A with an additional feature that the temperature can be independent of the stage in which it can be used.
  • Figures 27A to 27C shows different schemes for generation of the additives to be input to the different processing regions of the gasifier.
  • Figure 27D shows a
  • Figures 28A-C show different embodiments of feedstock input means to the gasifier;
  • Figure 28A shows a secondary feed fed to the primary feed screw;
  • Figure 28B shows the primary and secondary feed fed into a mixed hopper and conveyed via screw to the gasifier;
  • Figure 28C shows the same idea as Figure 28B but extended to two or more feeds.
  • Figures 29A-E show different designs for the connection the gasifier to the gas reformulating chamber (GRS);
  • Figures 29A and 29B show two designs where the GRS is attached to the bottom and top of the gasifier respectively;
  • Figure 29C shows the use of a hot-pipe to carry the gas from a gasifier to the GRS;
  • Figure 29D shows the use of two hot- pipes to carry the gas from two gasifiers to the GRS;
  • Figure 29E shows the use of a single hot-pipe to carry the gas from two gasifiers to the GRS.
  • Figures 3 OA-D depict various combinations of how the different function blocks processes of a gasification facility can be constructed, wherein “A” depicts function block A (a gasifier), “B” depicts a function block B (a residue conditioning system) and “C” depicts a function block C (a gas reformulating system).
  • A depicts function block A (a gasifier)
  • B depicts a function block B (a residue conditioning system)
  • C depicts a function block C (a gas reformulating system).
  • Figure 31 is a cross-sectional schematic of a gasifier with a single processing chamber directly connected to a residue conditioning system based on plasma torch.
  • Figure 32 shows one embodiment of a distributed control system for a gasification facility using a gasifier, GRS, GCS, GHS and a downstream application for the output syngas generated upstream.
  • Figure 33 A shows the schematic of a gasification system with a laterally oriented gasifier followed by a vertically oriented gasifier, in accordance with one embodiment of the present invention.
  • Figure 33B shows the schematic of a gasification system with a vertically oriented gasifier followed by a laterally oriented gasifier, in accordance with another embodiment of the present invention.
  • Figure 34 is a representation of the processing regions in a gasifier comprising three processing chambers, each with symmetric placement of the additive input elements to enable the formation of individual processing regions for drying, volatilization and carbon conversion, in accordance with one embodiment of the present invention.
  • Figures 35A to 351 show various embodiments for movement of reactant material from one processing chamber to another in a two-processing chamber gasifier; the movement of the reactant material is controlled using gravity in Figure 35 A; using gravity with sideways top valve in Figure 35B; using gravity with hopper in Figure 35C; using gravity with screw in Figure 35D; using a vertical screw in Figure 35E; using a horizontal extractor screw in Figure 35F; using a vertical screw with hopper in Figure 35G; using gravity with screw and hopper in Figure 35H; and a horizontal extractor screw and hopper in Figure 351 respectively.
  • the term 'about' refers to a +/-10% variation from the nominal value. It is to be understood that such a variation is always included in any given value provided herein, whether or not it is specifically referred to.
  • feedstock' and 'feedstock' are defined to refer to carbonaceous material that can be used in the gasification process.
  • suitable feedstock include, but are not limited to, hazardous and non- hazardous waste materials, including municipal wastes; wastes produced by industrial activity; biomedical wastes; carbonaceous material inappropriate for recycling, including non-recyclable plastics; sewage sludge; coal; heavy oils; petroleum coke; heavy refinery residuals; refinery wastes; hydrocarbon contaminated solids; biomass; agricultural wastes; municipal solid waste; hazardous waste and industrial waste.
  • biomass useful for gasification examples include, but are not limited to, waste wood; fresh wood; remains from fruit, vegetable and grain processing; paper mill residues; straw; grass, and manure.
  • the term 'reactant material' is defined to refer to any feedstock, including but not limited to partially or fully processed feedstock.
  • the term 'residue' generally refers to the residual material produced during processes for the gasification or incineration of carbonaceous feedstocks. These include the solid and semi-solid by-products of the process.
  • a residue generally consists of the inorganic, incombustible materials present in carbonaceous materials, such as silicon, aluminum, iron and calcium oxides, as well as a proportion of un-reacted or incompletely converted carbon.
  • the residue may include char, ash, and/or any incompletely converted feedstock passed from the gasification chamber.
  • the residue may also include materials recovered from downstream gas conditioning processes, for example, solids collected in a gas filtering step, such as that collected in a baghouse filter.
  • the residue may also include solid products of carbonaceous feedstock incineration processes, which may come in the form of incinerator bottom ash and fly ash collected in an incinerator's pollution abatement suite.
  • sensing element is used in the broadest sense to describe the aspect of any element related to the gas reformulation system that is configured to sense, detect, read, monitor, etc. one or more characteristics, parameters, and/or information of the system, inputs and/or outputs.
  • response element is used to describe the aspect of any element related to the gas reformulation system that is capable of responding to a signal.
  • a gasifier comprising one or more fluid conduits for converting carbonaceous feedstock into an off-gas and residual solid material.
  • the gasifier comprises a refractory-lined processing chamber having one or more fluid conduits located therein to facilitate the passage of fluid material such as gas into and/or out of the chamber.
  • a conduit facilitates the input of process additives and/or the exit of steam and/or off-gases from the processing chamber.
  • the gasifier comprises one or more input(s) for receiving feedstock, one or more residue outlets, and heating means to facilitate the conversion process and a control system for controlling various aspects of the gasification process.
  • the gasifier may be configured for recycling steam and/or off-gas and/or recycled heat back into processing chamber.
  • the gasifier may further comprise one or more material displacement control modules for facilitating movement of the reactant material through the gasifier, agitation or mixing means to facilitate mixing of reactant material with process additives.
  • the material displacement control modules and/or the agitation or mixing means may be operatively coupled to the control system.
  • the gasification of the carbonaceous feedstock can be subdivided into three stages, namely, drying, volatization and char-to-ash conversion. Accordingly, one or more processing regions may optionally be defined within the gasifier within each one of which a certain process such as drying, volatilization or carbon conversion or combinations thereof may be at least partially favoured.
  • the feedstock delivered into the gasifier undergoes a drying process under a temperature range between about 25°C and about 200°C, for example. In this temperature range, drying may also be accompanied by minor amounts of volatilization.
  • This process occurs mainly between about 350°C and about 800°C, for example, and may also be accompanied by a small remainder of the drying operation as well as a substantial amount of carbon conversion.
  • the composition of air supplied in this region is typically varied depending on the feedstock supplied (e.g. oxygen enriched or depleted air).
  • the gasifier can in general comprise of a large number of processing regions with a different proportion of drying, volatilization or carbon conversion occurring in each processing region.
  • the number of processing regions can be as many or as few as desired, without loss of generality.
  • the gasifier 1 may be oriented vertically, as illustrated schematically in Figures IA and IB, oriented horizontally, as shown in Figures 1C and ID.
  • Figures IA and IB show vertically oriented gasifiers 101, 201 respectively, in accordance with different embodiments of the invention.
  • the one or more feedstock inputs, 140, 240, placed at or near the top of the processing chamber 110, 210 allow for the entry of feedstock thereto.
  • output elements 135 disposed around the periphery of the processing chamber 110 are used for the extraction of off-gases therefrom, while the fluid conduit 120 within the processing chamber 110 is used for the injection of additives therein.
  • input elements 230 disposed around the periphery of the processing chamber 210 are used for the injection of additives therein while the fluid conduit 220 within the processing chamber 210 is used for the extraction of off-gases therefrom.
  • Figures 1C and ID show horizontally oriented gasifiers 301 and 401, respectively, in accordance with different embodiments of the invention
  • output elements 335 disposed around the periphery of the processing chamber 310 are used for the extraction of off-gases therefrom, while the fluid conduit 320 within the processing chamber 310 is used for the injection of additives therein.
  • input elements 430 disposed around the periphery of the processing chamber 410 are used for the injection of additives therein while the fluid conduit 420 within the processing chamber 410 is used for the extraction of off-gases therefrom.
  • the gasifier comprises one or more fluid conduits and optionally, one or more input elements and/or one or more output elements operatively disposed around a periphery of the chamber. These cooperate to facilitate the addition of process additives and/or the exit of steam and/or off-gases therefrom.
  • the additives injected into the processing chamber determine the chemical conditions therein and thus promote the determination of one or more processing regions within the gasifier within which a certain process such as drying, volatilization or carbon conversion may be at least partially favoured.
  • the location and shape of the fluid conduits can vary and is not limited to any shape explicitly mentioned herein.
  • the fluid conduit is a cylindrical tube centrally located within the processing chamber.
  • the fluid conduit is centrally located within the processing chamber but has a rectangular cross-section.
  • the fluid conduit has a tear drop shape.
  • the various shapes of the fluid conduits may be designed to optimize the dispersion of the process additives into the gasifier.
  • the different fluid conduits can vary in shape and size and can also be used for different functions.
  • the gasifier may comprise a first fluid conduit used for outputting off-gases and/or steam, and a second fluid conduit used for injecting additives.
  • the off-gas can be drawn out at either or both ends of the processing chamber by appropriate placement of a blower or other suction means as known in the art.
  • the multiple fluid conduits can be nested within one another, (e.g. concentric cylindrical tubes can be used for exit of off-gases and/or the entry of additives into the different processing regions) and/or distinctly located. Multiple fluid conduits can also be positioned and designed to act as stirring/mixing means.
  • the gasifier comprises three processing regions with the first processing region at least partially favouring drying, the second processing region at least partially favouring volatilization and the third processing region at least partially favouring carbon conversion, hi one embodiment and referring to Figure 2, these processing regions 11, 12, 13 may be vertically successive, and are defined by the placement of three sets of input elements, or groups thereof, around the processing chamber, for input of additives 30. Functional arrows show the input of the feedstock 40 and the output of the off-gases 35 using the fluid conduit and residue 50.
  • Figures 3A and 3B show two embodiments, where the gasifier comprises three processing regions, hi Figure 3A, input elements 531, 532, 533 disposed around the periphery of the processing chamber 510 allow for injection of additives into the three processing regions 511, 512, 513 while the two fluid conduits 520 located within, allow for the extraction of off-gases.
  • one fluid conduit 620 each is used for injection of additives and extraction of off-gases.
  • Input elements 631, 633 disposed around the periphery of the processing chamber 610 are used for injection of additives into the first and third processing regions 611 and 613, while output elements 638 disposed around the periphery of the processing chamber 610 are used for extraction of off-gases from the second processing region 612.
  • fluid conduits may be provided for supplying additives to and/or removing off-gases from (optionally for use in heat and/or by-product recycling, as discussed further below) the gasifier, in accordance with different embodiments of the present invention, as can any number or group of these fluid conduits may be provided with a header and be configured to be removed and/or replaced for maintenance and/or cleaning.
  • Figures 4A-B represent embodiments of the invention where more than one fluid conduits are included in the gasifier and gases pass there between.
  • the gases can pass between the conduits and/or walls; wherein the system has at least two conduits either channelling additives and/or off-gases.
  • the cross-flow nature of this configuration allows for better control over the bed temperature and conversion and also deal with wall- effects.
  • These fluid conduits may be in nested configuration.
  • cross-flow conditions may be promoted by careful design of the gasifier, and in particular, the design of the boundary zones between adjacent processing regions. These boundary zones do not have any additional reactions occurring, such as injection of process additives and/or off-gas extraction. As such, the boundary zones may be designed to have no holes in the wall and fluid conduit(s).
  • Cross-flow operation can be achieved in both horizontally and vertically oriented embodiments of the present invention, as shown in the Figure below.
  • the fluid conduits may be configured such that the off- gases may be extracted from each processing region independently, or extracted cooperatively from more than one processing region simultaneously. Similarly, the fluid conduits may be configured so that the process additives may be injected into each processing region independently, or in a coordinated fashion.
  • a first fluid conduit 1021 is configured to output the off-gases from the first processing region 1011 of the chamber 1010. The gases in the first processing region 1011 are mainly additives inputted thereto and the water vapour/steam from the material.
  • a second fluid conduit 1020 is used to output the off-gases from the second and third processing regions of the gasifier.
  • dedicated fluid conduits (1121, 1122) are used to output the off-gases from the first and second processing regions (1111, 1112).
  • the off-gas generated in the third processing region 1113 is outputted using a third fluid conduit 1123.
  • one or more of the fluid conduits may be in a nested configuration.
  • a first fluid conduit 1220 combines the off-gases from the first and third processing regions before transfer to a gas reformulating system.
  • a second fluid conduit 1222 is configured as an outer layer to the first fluid conduit 1220 and is configured to output the off-gases generated in the second processing region 1212.
  • Figure 6B shows a 3D schematic of a configuration of fluid conduits, such as the embodiment of Figure 6A.
  • the fluid conduit 1222 configured as the outer layer output the off-gases 1237 extracted from the second processing region. Off- gases in the two fluid conduits 1220 and 1222 do not mix with each other.
  • three dedicated fluid conduits 1321, 1322 and 1323 are utilized for independent extraction of off-gases from the three processing regions 1311, 1312, 1313 respectively.
  • Gas passage conduits 1321 and 1322 are nested and configured to output the gases therein in the upward direction, while the fluid conduit 1323 is configured to output the gases in the downward direction.
  • Figure 8A show an embodiment similar to that of Figure 7, except that all three fluid conduits 1421, 1422 and 1423, are nested and configured to output the gases therein in the upward direction.
  • Figure 8B shows a 3D schematic of the configuration of fluid conduits, shown in Figure 8A.
  • the three off-gas streams 1436, 1437, and 1438 are extracted using the three fluid conduits 1421, 1422 and 1423 respectively, and may be operatively linked to pipes outside the gasifier.
  • the fluid conduits may be configured so that the process additives may be injected into each processing region independently, or in a coordinated fashion.
  • Figures 9A-B and 1OA show different embodiments of the invention where additives are injected into the processing chamber using fluid conduit(s) located therein, and the off-gases are extracted separately or cooperatively from different processing regions using output elements disposed around the processing chamber.
  • additives are added to the gasifier via the fluid conduit 1520 and the off-gas streams 1536, 1537, 1538 from the different processing regions are extracted using a common jacket disposed around the processing chamber.
  • additives are added to the gasifier via the fluid conduit 1620 and the off-gas streams 1636, 1637, 1638 from the three processing regions 1611, 1612, 1613 respectively are extracted using dedicated jackets disposed around the processing chamber, which ensure that the off-gases from the various processing regions do not mix with each other.
  • additives are added to the gasifier 1701 using a nested configuration of dedicated fluid conduits 1721, 1722, 1723, and the off-gas streams 1736, 1737, 1738 are extracted using dedicated jackets disposed around the processing chamber 1710.
  • caps oriented downwards are placed over the extraction holes to stop the reactant material from entering and plugging the holes. Care should be taken that the particles big enough to plug the holes are not entrained up the caps. A worker skilled in the art will readily understand that the caps will have to be appropriately oriented for other embodiments of the present invention.
  • the holes on the fluid conduits do not plug as much since they are now injecting air rather than being the exit point.
  • the holes distributed around the processing chamber will have lower flow rates (more holes); so the pressure drop and velocity will not be as great, resulting in reduced plugging.
  • cleaning plugged holes is easier for holes distributed around the processing chamber than on the inside.
  • Different techniques for clearing plugged holes include: (a) a pressure spike to clear the holes; (b) scraping the holes with the agitator or other device; and (c) use of a small piston push though the holes from the outside jacket.
  • FIGS 12D-F Three additional design options for the holes are shown in Figures 12D-F.
  • the hole is cut with two different angles, thus reducing the chance of the reactant material passing though the hole;
  • a straight hole design is used. This design provides ease of manufacture and allows for the least amount of pressure drop, allowing for higher velocities for the same maintained pressure.
  • the hole is designed to direct the gas flow more laterally (with less pressure loss than the design of Figure 12D due to the lack of a 'corner', which reduces plugging and increase the contact with the ash close to the wall.
  • Straight hole designs promote ease of cleaning.
  • FIG. 13A-C show three different options, with arrows showing the direction of rotation if placed on holes in the shaft. A worker skilled in the art will understand that the protectors of Figures 13B-C will be modified if place on the outside wall.
  • the metal plate cover is designed to completely cover the hole and to release the gases sideways. With this design, the facades push ash away and over the holes.
  • a metal plate is bent around the holes to stop ash and agglomerates from grinding into the holes.
  • a metal flap covers the hole; however, when gases are to be ejected from the hole, the flap opens enough to release the pressure.
  • the design will need to account for the higher temperatures typically found in such gasifiers.
  • the processing chamber of the gasifier comprises an outer wall and a refractory-lined inner wall defining an inner volume, within which the one or more fluid conduits are located.
  • the carbonaceous feedstock is fed into the inner volume between the inner wall and the one or more fluid conduits.
  • one or more input elements and/or output elements, or groups thereof are disposed on the inner wall, around the processing chamber for facilitating the entry/exit of additives/off-gases to/from the inner volume.
  • the inner walls may vary in shape so long as the inner volume can accommodate the appropriate amount of reactant material for the designed residence time, and allow for a reasonable off-gas superficial velocity to be attained.
  • FIGS 14A-C show side-views of the inner volumes of three different embodiments of the present invention.
  • the three processing chambers share the following similarities: they comprise three vertically successive processing regions distributed within, with input elements used for injection of additives into them; and the processing chamber is directly connected to a gas reformulating system (GRS).
  • GRS gas reformulating system
  • the inner wall is a refractory-lined cylinder
  • the inner wall is refractory-lined and downward sloping
  • the inner wall is shaped such that each processing region 711, 712, 713 has a vertical section followed by an inwardly sloped wall.
  • the outer walls can also vary in shape.
  • the outer wall defines a cylinder whose length is between about 1 and 6 times its diameter, hi one embodiment, the cylinder's length is between about 1 and 2 times its diameter, hi one embodiment, the length is about 1.5 times its diameter.
  • Figure 15A shows a cross-section of an outer wall corresponding to the two different three-dimensional embodiments shown in Figures 15B and 15C.
  • Figure 16A shows another cross-section of an outer wall corresponding to a three-dimensional embodiment shown in Figure 16B.
  • Other appropriate shapes of outer walls for the descending bed processing chamber will be known to a worker skilled in the art.
  • a refractory lining protects the processing chamber from the effects of high temperatures and corrosive gases and minimizes unnecessary loss of heat from the process.
  • the refractory material is a conventional refractory material, which is well-known to those skilled in the art and which is suitable for use for a high temperature e.g. up to about 1800 0 C, un-pressurized reaction.
  • refractory material examples include, but are not limited to, high temperature fired ceramics, i.e., aluminum oxide, aluminum nitride, aluminum silicate, boron nitride, zirconium phosphate, glass ceramics and high alumina brick containing principally, silica, alumina, chromia and titania.
  • high temperature fired ceramics i.e., aluminum oxide, aluminum nitride, aluminum silicate, boron nitride, zirconium phosphate, glass ceramics and high alumina brick containing principally, silica, alumina, chromia and titania.
  • membranes are known in the art and as such a worker skilled in the art would readily be able to identify appropriate membranes based on the gasifier requirements.
  • the gasifier comprises a vertically oriented gasifier with a cylindrical outer wall and at least partially downward-sloping inner walls.
  • the downward-sloping inner walls may offer the following merits: (a) act as a passive aid in the movement of the reactant material through the processing chamber; (b) allow for successively smaller internal cross-sectional areas for the one or more vertically successive processing regions; and; (c) ensure that the thickness of the refractory wall is larger at the bottom of the descending bed processing chamber than at the top.
  • the successively smaller internal cross-sectional areas of the processing regions allow for all the processing regions to have the same height while still having successively smaller internal volumes, compatible with the shrinkage in volume of the reactant material as it passes through the one or more vertically successive processing regions.
  • the constant height of the processing regions makes the placement of the input/output elements easier from an engineering standpoint, while the larger thickness of the refractory walls at the bottom of the processing chamber is compatible with the higher temperatures thereat.
  • the physical design characteristics of a processing chamber are determined by a number of factors that can be readily determined by one skilled in the art.
  • the internal configuration and size of the processing chamber can be dictated by the operational characteristics through analyses of the chemical composition of the input feedstock to be processed.
  • Gasification requires heat and an oxidant such as oxygen and/or steam. Heating can occur directly by the heat released due to partial oxidation of the feedstock or indirectly by use of one or more heat sources known in the art. [0116] Therefore, other design factors include the type of heating means used and the position and orientation of the heating means used. These heating means are generally positioned within the processing chamber at the desired depth in order to concentrate the high temperature processing region where it is most effective, while simultaneously minimizing heat losses.
  • the heat source is pre-heated air injected into the processing chambers either obtained from air heaters or heat exchangers, both of which are known to a worker skilled in the art and fed through to each processing region using an independent air feed and distribution system, provided for example by an air box.
  • the air could also be injected through the fluid conduits.
  • the indirect heat source could either be circulating hot sand or an electrical heating element.
  • the heat required for gasification may also be obtained by recycling (discussed in detail below) sensible heat present in the output gas streams of the gasification and/or gas reformulation processes.
  • Various computer-based simulation and modeling tools can facilitate the physical design of the processing chamber by taking into account factors such as efficient heat transfer, gas flow, mixing of additives, etc.
  • Computer-based tools virtually eliminate the need for experimentation prior to preliminary system design and provide rapid confirmation of process characteristics and efficiency with any input waste stream. They also permit interactive iteration to optimize operational characterization for any particular system prior to system commissioning and facilitate real-time optimization of processes for non-homogeneous materials based on product gas characterization as input.
  • One such simulator is the Chemical Process Simulator, as detailed in U.S. Patent 6,817,388 (incorporated by reference). It uses the principle of minimization of Gibb's free energy to allow prediction of the product gas components at a specific temperature and specific set of input parameters.
  • flow modeling of the processing chamber may also be used in the design process to ensure proper mixing of the process inputs, to analyze impact of the kinetic effects, and to adjust the reaction temperature profile within the simulator. Flow modeling results also assist refractory design since all operating characteristics at the refractory surface can readily be identified.
  • the processing chamber design may incorporate various design features of various types of processing chambers known in the art, including but not limited to descending bed processing chambers, fixed-bed processing chambers, gravity-assisted vertical processing chambers, mechanically-assisted flow processing chambers, entrained flow processing chambers, and fluidised bed processing chambers, to name a few.
  • the processing chambers can further comprise one or more service ports to allow for entry for maintenance and repair.
  • Such ports are known in the art and can include sealable port holes of various sizes, hi one embodiment, access to a processing chamber is provided by a manhole at one end which can be closed by a sealable refractory lined cover during operation, hi one embodiment of the invention, a manhole is placed on both ends of a processing chamber for maintenance.
  • the processing chambers can include access ports sized to accommodate various conventional burners, for example natural gas or propane burners, to pre-heat the gasifier.
  • Additives may be input at multiple locations within the processing chamber to promote definition of each processing region therein and to facilitate efficient conversion of the feedstock into gas.
  • the type and quantity of the additives is selected to optimize the process reactions while maintaining adherence to regulatory authority emission limits and minimizing operating costs.
  • additives include but are not limited to air, oxygen-enriched air, nitrogen, oxygen, steam and ozone.
  • the injected additives play a key role in determining the chemical conditions (e.g. temperatures) within the processing chambers and thus the extents of the processing regions wherein different processes are at least partially favoured.
  • Additives fed into the processing chamber can include steam, pre-heated air etc, and serve to improve the quality of the product syngas.
  • the position, orientation and number of the injection ports for these additional additives also have to be considered in the design of the processing chamber to ensure that they are injected where they will promote efficient reaction to achieve the desired conversion result.
  • Air or oxygen input can be used to maximize carbon conversion (i.e., minimize free carbon) and to maintain the optimum processing temperatures while minimizing the cost of input heat.
  • the quantity of both additives can be established and rigidly controlled as identified by the outputs for the feedstock being processed.
  • the amount of air injection is established to minimize the cost of heating while ensuring the overall process does not approach any of the undesirable traits associated with incineration (such as unwanted dioxins, furans, NOx, SOx in product gas, metals in ash and lower carbon conversion), and satisfies the emission standards requirements of the local area.
  • a secondary feedstock stream is also introduced as a process additive.
  • This feedstock stream can be dynamically manipulated by the global control system depending on the downstream parameters of the gasifier such as the quality of the product gas, pressure etc as sensed by the sensing elements.
  • a typical secondary feedstock is high carbon feedstock such as plastics, rubber such as tires and the like, and other such feedstock as will be readily apparent to the person of skill in the art.
  • a plurality of steam and/or air streams may be injected into the one or more processing chambers. These streams are strategically oriented to direct steam and/or air into the high temperature regions.
  • additional air/oxygen streams may optionally be injected.
  • nitrogen is used as an additive instead of air in the processing region promoting drying to avoid the possibility of combustion.
  • the input elements distributed around the processing chamber are used for injection of additives into the reactant material contained within.
  • the resulting off-gases in the different processing regions are collected using the one or more fluid conduits located in the inner volume of the processing chamber.
  • the gasifier comprises three vertically successive processing regions 1211, 1212, 1213 with three additive input elements 1231, 1232, 1233 or groups thereof, respectively distributed around the processing chamber 1210.
  • the flow of the additives is substantially cross-flow with respect to the vertically downward movement of the reactant material through the processing regions.
  • the additives are injected using the fluid conduits within the inner volume of the processing chamber 1710 and the off-gases are extracted using the output elements 1737, 1738, 1739 distributed around the processing chamber.
  • the flow of the additives is substantially cross-flow with respect to the vertically downward movement of the reactant material through the inner volume of the processing chamber.
  • agitators can be used to promote mixing of the reactant material.
  • the actual location of the input elements around the processing chamber may be determined based on one or more of the following factors: (a) maximize heat transfer; (b) maximize contact with carbon; (c) minimize pressure loss; (d) avoid plugging; (e) minimize potential for gas channelling; (f) maximize ease of replacement and clean-up.
  • the additives expand outwards in the bed to the outside edge of the processing chamber where the resulting gas is collected and piped off.
  • the gases can then pass to a reformulation chamber, or handled in a similar manner to alternative designs.
  • Good mixing promotes an even treatment of the reactant material with additives and avoid combustion and around the one or more processing chambers, bridging/agglomeration in the regions contiguous to the input of the additives where the concentration of oxygen is higher. As the gas expands outward from the center it will react with the reactant material producing more gas resulting in an even gas flow.
  • the input of additives may be actively controlled by a common response element configured to provide a pre-selected quantity or input rate of additives (e.g. set absolute or relative input) for a given sensed process characteristic (e.g. process temperature, pressure, throughput, etc. ; product gas quality, quantity, composition, pressure, flow, heating value etc.; feedstock input rate, quality, composition, etc; and the like), or again controlled by distinct response elements, possibly operatively linked via a same local, regional and/or global control system.
  • a common response element configured to provide a pre-selected quantity or input rate of additives (e.g. set absolute or relative input) for a given sensed process characteristic (e.g. process temperature, pressure, throughput, etc. ; product gas quality, quantity, composition, pressure, flow, heating value etc.; feedstock input rate, quality, composition, etc; and the like), or again controlled by distinct response elements, possibly operatively linked via a same local, regional and/or global control system.
  • the movement of the reactant material through the gasifier may optionally be facilitated via one or more material displacement control modules, thus allowing the overall gasification process to be enhanced, if not optimized for a given set of process conditions.
  • the material displacement control module can also be specifically optimized to minimize the carbon content in the residue, hi one embodiment of the invention, this is achieved using a plug flow pattern for the movement of the reactant material and a total control over the residue removal rate. It may also optionally incorporate means to break up residue agglomerates that can cause jamming at the residue outlets of the gasifier.
  • one or more material displacement control modules operatively control one or more process devices and/or mechanisms configured to control a displacement or a rate of displacement of the reactant material through the processing regions, thereby promoting the efficient processing of the material therein.
  • the material displacement control module may further be associated with, or integrated within a local, regional and/or global control system adapted to actively control various elements of the gasifier in response to sensing one or more process characteristics, either within the gasifier, or external thereto, for example, in a downstream process or application of the product gas.
  • a local, regional and/or global control system adapted to actively control various elements of the gasifier in response to sensing one or more process characteristics, either within the gasifier, or external thereto, for example, in a downstream process or application of the product gas.
  • further refinement of the material processing may be achieved to meet downstream needs, for example, when the product gas, or a further processed derivative thereof, is used for a selected downstream application.
  • the combined control of the gasification process may be implemented so to maximise gasification of the material, for example, to meet environmental regulations where such regulations exist, and/or to minimise an energetic impact of the process.
  • the material displacement control module may be configured to operate under pre-set operational parameters, for example, allowing for a substantially constant residence time of the material in each processing region, or again, may be configured to operate under dynamically updated or generated operational parameters adapted to optimise processing of the material to achieve a given result, hi either scenario, the material displacement control module, and any control system operatively coupled thereto, may comprise one or more sensing elements for sensing one or more process characteristics, such as process temperature(s), pressure(s), reactant composition, product gas composition, and adjust one or more process devices, such as mechanisms and/or devices operatively controlled by the material displacement control module for enabling a controlled displacement of the material through the processing regions within the gasifier, in response to these characteristics.
  • process characteristics such as process temperature(s), pressure(s), reactant composition, product gas composition
  • a vertically oriented gasifier comprises one or more material displacement control modules that actively control the downward movement of the reactant material through the various processing regions of the gasifier. This is in contrast to standard descending bed gasifiers that rely on the gradual consumption of the reactant material in the gasifier to move the reactant material downwards.
  • various cooperative devices and/or mechanisms may be controlled by the one or more material displacement control modules to implement a downward displacement of the material, either by direct control of material displacement between each processing region, or by controlled extraction of reactant material from a lowermost processing region thereby indirectly controlling a downward displacement of the reactant material from an uppermost processing region toward the lowermost processing region under gravity, or using any combination thereof.
  • the material displacement control module will be adapted for a given embodiment to enable the controlled displacement of material through the one or more processing regions.
  • the material displacement control module can be configured to operate one of a variety of mechanisms or devices known in the art for enabling displacement of material from one region to another. Examples include, but are not limited to rotating arms, rotating wheels, rotating paddles, moving shelves, pusher rams, screws, conveyors, and combinations thereof.
  • the factors involved in the choice of a particular type of device or mechanism operated by the material displacement control module include but are not limited to: (a) controllability & speed: how well can the flow of the reactant material through the vertically oriented gasifier be controlled accurately; (b) variance in reactor flow: if additives are added below the material displacement control module, is there a disruption to the flow and is the disruption manageable; and/or (c) power requirements and durability: how much energy and maintenance is required for proper operation of the device or mechanism, e.g. rotating grates require more maintenance than screws and pusher rams when properly designed.
  • Figures 17A-B depict a vertically oriented embodiment of the invention in which the material displacement control module comprises a rotating paddle 81 at the bottom of a processing chamber 10 which moves the reactant material 41 out of the processing chamber through a small residue outlet.
  • the material displacement control module comprises a rotating paddle 81 at the bottom of a processing chamber 10 which moves the reactant material 41 out of the processing chamber through a small residue outlet.
  • a hat covering 82 is placed over the residue outlet.
  • Limit switches may be optionally used to control the speed of the bar rotation and thus the rate of removal of residue.
  • some of the structural details of the chambers such as the fluid conduits and the feedstock inputs are not shown.
  • Figures 18A and 18B depict vertically oriented embodiments of the invention in which the material displacement control module comprises a set of extractor screws 83 at the bottom of the processing chamber 10 to move the residue out of the processing chamber. Serrations on the edge of the extractor screw flight helps in the breaking up of the residue agglomerations that could otherwise result in jamming at the residue outlet 50 of the gasifier. A hat covering 82 is not required if the residue outlet is moved away from the processing chamber, as for the embodiment shown in Figure 18B. Limit switches may be optionally used to control the speed of the screws and thus the rate of removal of residue. For clarity, some of the structural details of the chambers such as the fluid conduits and the feedstock inputs are not shown.
  • Figure 19 depicts one vertically oriented embodiment of the invention in which the material displacement control module comprises a single thin pusher ram 85 at the bottom of a processing chamber 10 which moves the residue out of the processing chamber through a small residue outlet 50.
  • a hat covering 82 may or may not be required as shown in figure 19A.
  • Limit switches may be optionally used to control the length of the pusher ram stroke and thus the amount of residue moved with each stroke. As the pusher rams used are thin, only a small amount of residue is moved out of the processing chamber. For clarity, some of the structural details of the chambers such as the fluid conduits and the feedstock inputs are not shown.
  • the material displacement control module may comprise an array of one or more devices (e.g. pusher rams) within each processing chamber, each of which is used to actively control the movement of the reactant material from one processing region to the next until the final pusher ram pushes the residue out of the processing chamber.
  • the reactant material is actively controlled through the entire height of the processing chamber.
  • suitable moving elements include, but are not limited to, a shelf/platform, pusher ram, plough, screw element or a belt.
  • the guide element can include one or more guide channels located in the bottom wall of the processing chambers, guide tracks or rails, guide trough or guide chains.
  • the guide element can include one or more wheels or rollers sized to movably engage the guide element,
  • the guide engagement member is a sliding member comprising a shoe adapted to slide along the length of the guide track.
  • the shoe further comprises at least one replaceable wear pad.
  • the material displacement control module may be powered using a motor and drive system, or other such means as readily known in the art.
  • the motor means is an electric variable speed motor which drives a motor output shaft selectably in the forward or reverse directions.
  • a slip clutch could be provided between the motor and the motor output shaft.
  • the motor may further comprise a gear box.
  • operation of the material displacement control module can be implemented by a hydraulic or pneumatic system, chain and sprocket drive, or a rack and pinion drive.
  • These methods of translating the motor rotary motion into linear motion have the advantage that they can be applied in a synchronized manner at each side of the material displacement control module (e.g. a pusher ram) to assist in keeping the mechanism aligned and thus minimize the possibility of jamming.
  • the use of two chains provides a means of maintaining angular alignment without the need for precision guides.
  • Figure 35A-I shows a variety of different devices and/or mechanisms that can be used by the material displacement control module for displacement of reactant material from one processing chamber 10 to another.
  • the options in this figure are merely exemplary and other appropriate designs for such devices/mechanisms can be considered to be within the scope and nature of the invention disclosed herein.
  • material displacement control modules can also be appropriately designed for horizontally oriented embodiments of the present invention.
  • the processing chamber is substantially horizontal and the material displacement control module is a plurality of rollers with horizontal and parallel axes in an inclined plane.
  • An example of a plurality of rollers is the Dusseldorf/Babcock grate. See, for example, U.S. Patent No. 5,967,064 and U.S. Patent No. 5,448,957.
  • An extractor screw as shown in Figure 2OA, may be used to output the ash generated in the gasifier through the one or more residue outputs.
  • the hollow shaft of the such extractor screws may be used as a fluid conduit for the injection of process additives to enhance the carbon conversion process.
  • process additives may include additional air and/or steam.
  • the injection of these additives may be thus achieved using holes in the screw, or alternatively, using holes in the walls of the chamber.
  • a screw is used to move the reactant material from one end of the chamber to the other.
  • This screw and the outer walls of the chamber may be partially perforated to allow the gas to cross the reactant material, as shown in Figure 2OB.
  • the screw thus act as the fluid conduit for either additives or off-gases.
  • FIG. 21 Three alternate injection options are shown in Figure 21.
  • an inner pipe is installed which has a hole (or line of holes) along the bottom where the air can reach the screw's shaft and exit into the ash. Bars are welded onto the inner pipe to restrict the air flow towards the bottom of the screw.
  • the air is injected though the outer wall surrounding the screw.
  • the one or more processing chambers of the gasifier may comprise a mixing/agitation means for promoting efficient exposure of the reactant material to the additives thus promoting efficient gasification.
  • the mixing means reduces gas channelling, a condition where the additives such as pre-heated air burns a path through the bed, resulting in more additives travelling down that 'channel' avoiding the reactant material completely.
  • the passage of additives such as pre-heated air into the gas phase also called 'breakthrough', can cause rapid combustion with gas phase combustibles, agglomeration of the reactant material and channel burning. Good mixing also stabilizes the gas composition and reduces the risk of downstream gas explosion.
  • Agitation/mixing can be achieved though various mechanical and/or sonic means known to one skilled in the art, whereby part of the reactant material is moved in relation to the rest of the reactant material. Such agitation results in better bed settling and movement of the material to avoid localized melting or slagging when not ideal.
  • Such agitation means may comprise, for example, a rotating shaft controlled using a motorized drive.
  • These agitator shafts can also be operated, in one embodiment, as a sensing element of an integrated global control system wherein torque measurements on these shafts can serve as an indicator of the pile height, especially if the agitator has multilevel flights.
  • torque measurements on these shafts can serve as an indicator of the pile height, especially if the agitator has multilevel flights.
  • two agitator shafts may be used which clean each other as they rotate, thus knocking off agglomeration.
  • agitation is achieved using a rod or a specially shaped metal tool that is mechanically driven to move in a pattern or random path through the bed material. It is generally thin and aerodynamic enough that reactant material does not get jammed on the agitator and the agitator does not get stuck on the reactant material.
  • Figure 22 is a diagrammatical representation of a mixing device for mixing reactant material and additives within a gasifier, in accordance with one embodiment of the present invention, wherein the mixing device comprises a spinner, screw and/or toothed wheel 46.
  • FIGS 23 A-D are diagrammatical representations of different mixing devices for mixing reactant material and additives within a gasifier, in accordance with different embodiments of the present invention, wherein the mixing device comprises one or more agitator panels such as one or more flat panels 47 as illustrated in a front view in Figure 23A and in a side view in Figure 23C; one or more V-Shaped panels 48 as illustrated in a side view in Figure 23B; and one or more single sloped panel 49 as illustrated in a side view in Figure 23D.
  • the mixing device comprises one or more agitator panels such as one or more flat panels 47 as illustrated in a front view in Figure 23A and in a side view in Figure 23C; one or more V-Shaped panels 48 as illustrated in a side view in Figure 23B; and one or more single sloped panel 49 as illustrated in a side view in Figure 23D.
  • FIGS 24A-E are top plan representations of different mixing devices for mixing reactant material and additives within a gasifier, in accordance with different embodiments of the present invention, wherein the mixing device comprises one or more agitator panels such as a fiat panels/spokes as illustrated in Figure 24A; a V-Shape panel/spokes as illustrated in Figure 24B; an off-set panel/spokes as illustrated in Figure 24C; rotating panel/spokes as illustrated in Figure 24D); and a sloped panel as illustrated in Figure 24E.
  • the mixing device comprises one or more agitator panels such as a fiat panels/spokes as illustrated in Figure 24A; a V-Shape panel/spokes as illustrated in Figure 24B; an off-set panel/spokes as illustrated in Figure 24C; rotating panel/spokes as illustrated in Figure 24D); and a sloped panel as illustrated in Figure 24E.
  • FIGs 25A to 25D are top plan representations of a gasifier comprising one or more mixing devices in accordance with different embodiments of the present invention, wherein the mixing devices comprise a flat panel moving in a circular motion as illustrated in Figure 25A; two flat panels moving in a circular motion as illustrated in Figure 25B; a flat panel moving in a bi-directional circular motion as illustrated in Figure 25C; and multiple rotating agitators as illustrated in Figure 25D, wherein rotations may be clockwise and/or counter-clockwise (as illustrated).
  • the off-gas produced in the gasifier is generally at high temperatures
  • different techniques described herein can be used to capture the sensible heat present in the off-gas and recycle it to the gasification system to enhance the thermodynamic efficiency of the overall gasification process.
  • the captured heat can be used to heat the additives injected into the different processing regions. Referring to Figure 26, different schemes used for generating the additives injected into the different processing regions are described below.
  • the hot off-gases generated in the gasifier is cooled down in three cascaded heat exchangers 2961, 2962, 2963 heating three separate fresh flows of additives which are then directed as process additive streams 2931, 2932, 2933 into the different processing regions 2911, 2912, 2913.
  • the heating of the flows of additives to generate the process additive streams 3031, 3032, 3033 is achieved in three heat exchangers 3061, 3062, 3063 in parallel configuration.
  • the three process additive streams 3131, 3132, 3133 are generated from a single fresh flow of additives.
  • the fresh flow of additives is heated in low temperature heat exchanger 3161, and then divided into two flows, one of which is used as the process additive stream 3131 for the first processing region 3111.
  • the second flow undergoes heating in the medium-temperature heat exchanger 3162, and is also divided into two flows, one of which is used as the process additive stream 3132 for the second processing region 3111.
  • the remaining flow undergoes heating in the high-temperature heat exchanger 3163 and is used as the process additive stream 3133 for the second processing region 3113.
  • the hot off-gases heats a single gaseous flow of additives.
  • the heated flow is then divided into three flows, and fresh, cold flows of additives are added as appropriate to each to obtain the required temperatures for the resulting process additive streams 3231, 3232, 3233, before being directed into the respective processing regions 3211, 3212, 3213 of the gasifier.
  • Figure 26E shows an embodiment where the off-gases and/or stream 3336 obtained from the first processing region 3311, configured to at least partially promote drying, is withdrawn and heated in the high-temperature heat exchanger 3363 before being fed back into the third processing region 3313 of gasifier configured to at least partially promote carbon conversion.
  • This recycled stream ensures that the necessary amount moisture is available to facilitate the carbon conversion process.
  • Figure 26F presents an embodiment where the off-gases and/or steam 3436 from the first processing region 3411, configured to at least partially promote drying, is withdrawn from the gasifier 3401, passed through a condenser to remove the moisture therefrom, and after heating in low temperature heat exchanger 3461 is fed back into the first processing region 3411. To account for any gas leak in the condenser, a small fresh flow of gaseous additives may be mixed with the recycled flow.
  • Figure 26G shows an embodiment where a single flow of additives is divided into two flows after being heated in a low temperature gasifier 3561.
  • One of these flows 3531 is fed directly into the first processing region 3511 of the gasifier, configured to at least partially promote drying, while the second flow is heated in the high temperature heat exchanger 3563 and split up into the two process additive streams 3532, 3533 for the latter two processing regions.
  • Figure 26H presents an embodiment that allows for switching of the flows of additives between the processing regions depending on their composition.
  • the additive flow, with a higher oxygen concentration, from the low temperature heat exchanger 3661 is directed into the processing region 3612, configured to at least partially promote volatilization, while the additive flow, with a lower concentration of oxygen, from the middle temperature heat exchanger 3662 goes into the processing region, configured to at least partially promote drying.
  • a selection of the most effective heat exchange scheme between input and output gaseous flows depends on the composition of the solid material and gaseous additives employed for the gasification process considered.
  • input flows of air 3731, 3732, 3790 and water 3791 are directed into a low-temperature heat exchanger 3761.
  • the additive flow 3731 which may include the heated air and/or water, and/or a part thereof, is injected into the first processing region 3711.
  • the remaining air flow 3732, after preheating in the low- temperature heat exchanger 3761 is sent to a medium-temperature heat exchanger 3762 where it is heated to the temperature of about 400°C before it is injected (or a part thereof) into the second processing region 3712.
  • the water flow 3791 after evaporating and heating in the low-temperature heat exchanger 3761 is mixed with the air flow 3790 forming the wet air 3733.
  • the wet air flow 3733 after heating in the medium and high-temperature heat exchangers 3762, 3763 respectively, is at a temperature of about 600°C and is injected into the third processing region 3713. All the heat exchangers are heated using the hot gases generated by the gasifier or from a gas reformulating system operatively coupled thereto. [0137]
  • the completeness of the gasification process is enhanced by an increase in the temperature of the additives and the concentration of steam (or carbon dioxide) in it.
  • a hydrogen burner 65 is utilized to produce high temperature steam which is subsequently mixed and distributed with the heated gaseous flow.
  • the high temperature steam can conceivably be generated in a two stage process where, at the first stage, the input flow of water 99 is decomposed into hydrogen and oxygen in the electrolyser 64 and, at the second stage, the oxygen and hydrogen produced are combusted in the hydrogen burner 65 generating high temperature steam (temperature up to 2500-3000°C). Due to the high temperature of the steam generated it contains a large amount of highly reactive free radicals which promote the carbon conversion process partially favoured in the final processing region of the gasifier.
  • the gases from an earlier processing region(s) are used as additives in a later processing region(s) of the gasifier.
  • the gas generated in the first processing region, predominantly favouring drying is divided into two flows. The first flow is purified and vented, while the second one is recycled by mixing with the flow of air.
  • the flow of air and the flow of steam, obtained from the flow of water, constitute the mixed flow coming into the third processing region, wherein carbon conversion is the dominant process.
  • the recycling may permit (i) to reduce the flow of process water as a result of its replacement by the moisture contained in the reactant material (due at least in part to the fact that in this configuration the evaporated water and the sensible heat of the water and the syngas are used more effectively); (ii) an increase in the concentration of the combustible components in the final composition of syngas as a result of reducing the flow of nitrogen coming into the system with the air. As a consequence, less heat is required to carry out the gasification process resulting in enhanced thermodynamic efficiency. Recycling of off-gases generated during drying is extremely efficient if the moisture content of the input feedstock is high.
  • the heat recycling system is modified to reduce the amount of heat exchangers.
  • the flow of water is evaporated and, along with the flow of air, is heated in a high temperature heat exchanger to the temperature of about 600°C needed for promoting carbon conversion.
  • Gaseous flows are withdrawn from the hot flow in order to mix with the flows of "fresh" air and.
  • the correct selection of mass flow rates for these flows provides the temperature ranges of the gaseous flows required for promoting the drying and volatilization processes partially favoured within the first and second processing regions respectively.
  • the rest of flow is mixed with the flow of steam constituting the flow injected into the processing region promoting fixed carbon conversion.
  • the gasifier includes a material feeder system comprising one or more input feed ports catered to any physical characteristics of the input feedstock, each of which feed directly into the gasifier.
  • the material feeding subsystem consists of a feed hopper and a screw conveyor used to transport feedstock to the gasifier.
  • the material fed into the gasifier can be partially processed reactant material from an upstream gasifier.
  • the feed hopper acts as a buffer for the material ready to be fed into the gasifier.
  • the hopper can optionally have high and low level indicators that control the flow into the hopper and are optionally under the control of the process controller to match the feed rate to process demands.
  • the material feeding subsystem can further comprise an additional entry to accept a secondary feed (usually high carbon feedstock such as shredded plastic), thereby enabling quick response to process demands for higher or lower carbon input to meet the required gas quality for the downstream applications.
  • a secondary feed usually high carbon feedstock such as shredded plastic
  • FIG. 28B various embodiments of the invention can be envisioned, whereby the different feed streams are either mixed together in a common hopper before insertion into the gasifier or not.
  • the gasifier has a separate feeding subsystem for feeding the high carbon feedstock into the gasifier.
  • a more general case can be considered where there are more than two feed streams as well.
  • the material feeding system consists of a rectangular feedhopper and a hydraulic assisted ram.
  • a gate may be installed in the middle of the feed chute to act as a heat barrier between the processing chamber and the feedhopper.
  • Limit switches on the feeder control the length of the ram stroke so that the amount of material fed into the processing chamber with each stroke can be controlled.
  • the primary material feeding system may also be modified to accommodate the feeding of boxes, the form in which hospital biomedical type waste is provided for processing.
  • a rectangular double door port will permit the boxes to be fed into the primary feed hopper where the hydraulic ram can input them into the processing chamber.
  • an auger can be inserted hydraulically into the processing chamber to provide a granular waste material feed.
  • ram, rotary valve, top gravity feed are examples of other feeders that can be used in the present context to facilitate the introduction of desired feedstocks.
  • liquids and gases can be fed into the processing chamber simultaneously through their own dedicated ports.
  • the feedstock will pass through a pre-processing system before being fed into the feedstock input means.
  • the pre-processing subsystem may comprise a shredder to reduce the as-received feedstock to a size more suitable for processing.
  • components of the feedstock may include materials large enough to jam the shredder, the shedder is optionally equipped to stop when a jam is sensed, automatically reverse to clear the jam and then restart. If a jam is still detected the shredder will shut-down and send a warning signal to the controller.
  • Appropriate shedder and shedder designs are known in the art.
  • the pre-processing subsystem may also include a magnetic pick-up located above the conveyor to avoid the undesirable feeding of excessive amounts of metal through the gasifier.
  • a magnetic pick-up located above the conveyor to avoid the undesirable feeding of excessive amounts of metal through the gasifier.
  • Appropriate magnetic pick-ups are known in the art and consist of a powerful magnet over a pick conveyor belt to attract any ferrous metal that may be present in the shredded waste.
  • a non-magnetic belt can run across the direction of the pick conveyor, between the magnet and the feedstock so that any metal attracted to the magnet gets moved laterally away from the feedstock stream. When the metal has been moved away from the magnet it can be dropped onto a pile that is either disposed or sold.
  • the off-gas streams from the different processing regions may be kept separate or merged before being sent to a storage tank for future use or for further processing in a gas reformulating system (GRS).
  • GRS gas reformulating system
  • Off-gases generated in the gasifier may need to be reformulated to obtain a gas of a desired composition, for compatibility with either downstream applications, environmental regulations or other factors.
  • the gasifier is connected to a gas reformulating system (GRS) either directly or via piping for the reformulating of off-gas 2 derived from gasification of carbonaceous feedstock 4 into a reformulated gas of a defined chemical composition 99.
  • GRS gas reformulating system
  • Figure 29 shows different embodiments for connection of one or more gasifiers 1 to the reformulating chambers 94.
  • the GRS uses heat from one or more plasma torches to dissociate the gaseous molecules thereby allowing their recombination into smaller molecules useful for downstream application, such as energy generation.
  • the air or other gases entering the plasma torch pass through the high potential electrical field and are heated to temperatures of 3000-5000°C.
  • the plasma torch gas contains highly reactive free radicals and ions which together with the high temperature promote the gas reformulation process.
  • the GRS may also comprise gas mixing means, process additive means, and a control system with one or more sensors, one or more process effectors and computing means to monitor and/or regulate the reformulating reaction.
  • the off-gas from the gasifier can be sent to other treatment processes to improve its quality (e.g. lower the quantity of tars) and to maintain heating value, hi one embodiment of the invention, a low temperature GRS is used, which may not result in cracking of any tars present therein, but results in the conversion of the gas to a different composition tailored for a particular downstream application.
  • a low temperature GRS is used, which may not result in cracking of any tars present therein, but results in the conversion of the gas to a different composition tailored for a particular downstream application.
  • a hydrogen burner is used to react oxygen and hydrogen to produce ultra-high temperature steam (>1200°C). This steam can be applied to the off-gas to achieve gas reformulation and increase its heating value. This technique has similar energy efficiency as a plasma torch. As mentioned earlier, hydrogen burners can also be used to produce the additives to the lowermost processing region of the gasifier, than to the off-gas stream itself.
  • a chemical scrubber is applied to remove tars, if present, from the off-gas. Once in the liquid phase they could be collected or chemically treated for disposal/sale, hi one embodiment, a catalytic bed (fluidized or fixed) is used for gas reformulation with the addition of reactive additives.
  • a cold fluidized sand bed is used.
  • a material such as sand, ceramic etc is used to allow the warm off-gas to cool just enough so that tars, if present, condenses.
  • the condensed tars collects on the particle surface and the particle gets heavier and falls out of fluidization.
  • the fluidized bed or fixed tower is cleaned/cooled using water which can wash off the tars to be processed later.
  • the sand can also be cooled and recycled back into the process while the tars can be recycled back into the gasifier to stabilize the gas stream composition or sent to post-processing/sale/disposal. If the former, additional steam/air is injected with the tars to convert them into useable syngas.
  • the response of the gas stream composition may be faster than if the feed is changed suddenly.
  • the obtained syngas after the plasma-based reformulator is directed into a heat recycling system before it may be sent to a gas conditioning system and/or a gas homogenization system and/or a storage tank.
  • the heat recycling system captures the sensible heat present in the syngas stream and recycles this heat to the gasification process to enhance the efficiency thereof.
  • the gas conditioning system serves to remove particulate matter and other impurities from the syngas while the gas homogenization system serves to smooth out any time variations in the composition and pressure of the syngas by providing adequate mixing means and residence time within a homogenization chamber.
  • a storage tank is optionally used if the conditioned, homogenized syngas needs to be stored for future use. Otherwise, the conditioned, homogenized syngas can be used for downstream applications such as gas engines, boilers etc. Excess syngas can also be disposed of safely using a flare stack.
  • One or more residue outlets are used to remove the residue out of the final processing region of the gasifier.
  • the configurations in which the residue exit the processing chamber are dependent on the design and function of the subsequent process and can be readily determined by one skilled in the art.
  • the residue is removed from the gasifier by the one or more material displacement control modules.
  • the residue can be removed into, for example, an ash collection gasifier or to a water tank for cooling as is known in the art, from where it is transmitted through a conduit under control of a valve, to a point of discharge, hi one embodiment of the invention, the residue from the gasifier is sent to another gasifier for further gasification. This is particularly useful if the gasifier is not able to achieve thorough volatilization and carbon conversion.
  • the residue is, moved to a residue conditioning system which is either directly connected to the gasifier or connected via a conveyor, hi the residue conditioning system, plasma arc heating is used to convert the residue (char, ash) to slag by raising the temperature of the residue to the level required for complete melting and homogenization to guarantee trouble free, continuous and automatic (i.e. unattended) slag removal.
  • Other heating mechanisms can also be used in other embodiments of the residue conditioning system, but usually result in a slag of poor quality.
  • the molten slag is quenched in a water tank to form a vitreous, solid slag that can either be used in the construction industry or disposed off in a non-hazardous manner in landfills.
  • the slag contains heavy metals and other pollutants and is non-leaching.
  • Product gases generated in the residue conditioning system is sent to the gas conditioning system either after passing through the gas reformulating system or otherwise. These gases are generally high in CO concentration from the fixed carbon in the residue [0160]
  • the residual particles collected in the gas conditioning system can be sent back to the residue conditioning system for conversion to molten slag and quenching.
  • the gas can reach the gas conditioning system either directly or through a secondary gas conditioning system.
  • Figure 31 shows the particular implementation of the gasifier 1 where a residue conditioning system 92 based on a plasma-torch 93 is interfaced in a vertically successive fashion to the processing chamber 10 of the claimed invention.
  • the gasifier of the invention can be combined with various other systems, such as a residue conditioning system, gas reformulating system, gas conditioning system, gas homogenization system, to form a complete gasification facility.
  • This facility will take in carbonaceous feedstock and convert it into a refined, conditioned and homogenized syngas that can be used for various downstream applications.
  • the overall gasification facility can be controlled using a global control system to ensure that the overall process meets the requirements set by the particular downstream application and by the relevant regulatory standards.
  • a control system 98 for an overall gasification facility is shown in Figure 32.
  • gasifier of the present invention can also take in partially processed carbonaceous reactant material from another gasifier and/or output its partially processed reactant material to another gasifier.
  • upstream or downstream gasifiers can be horizontally or vertically oriented, as shown in the two embodiments of Figures 33A and 33B.
  • An optional control system may be provided to control one or more processes implemented in, and/or by, the gasifier, or affecting any downstream process or application of the gas produced thereby, and/or provide control of one or more process devices contemplated herein for affecting such processes.
  • the control system may operatively control various processes related to the gasifier and/or related to one or more global, upstream and/or downstream processes implemented within a gasification system comprising such a gasifier, and thereby adjusts various control parameters thereof adapted to affect these processes for a defined result.
  • sensing elements and response elements may therefore be distributed throughout the controlled system(s), or in relation to one or more components thereof, and used to acquire various process, reactant and/or product characteristics, compare these characteristics to suitable ranges of such characteristics conducive to achieving the desired result, and respond by implementing changes in one or more of the ongoing processes via one or more controllable process devices.
  • the optional control system generally comprises, for example, one or more sensing elements for sensing one or more characteristics related to the system(s), processe(s) implemented therein, input(s) provided therefor, and/or output(s) generated thereby.
  • One or more computing platforms are communicatively linked to these sensing elements for accessing a characteristic value representative of the sensed characteristic(s), and configured to compare the characteristic value(s) with a predetermined range of such values defined to characterise these characteristics as suitable for selected operational and/or downstream results, and compute one or more process control parameters conducive to maintaining the characteristic value within this predetermined range.
  • a plurality of response elements may thus be operatively linked to one or more process devices operable to affect the system, process, input and/or output and thereby adjust the sensed characteristic, and communicatively linked to the computing platform(s) for accessing the computed process control parameter(s) and operating the process device(s) in accordance therewith.
  • control system provides a feedback, feedforward and/or predictive control of various systems, processes, inputs and/or outputs related to the conversion of carbonaceous feedstock into a gas, so to promote an efficiency of one or more processes implemented in relation thereto.
  • various process characteristics may be evaluated and controllably adjusted to influence these processes, which may include, but are not limited to, the heating value and/or composition of the feedstock, the characteristics of the product gas (e.g. heating value, temperature, pressure, flow, composition, carbon content, etc.), the degree of variation allowed for such characteristics, and the cost of the inputs versus the value of the outputs.
  • Continuous and/or real-time adjustments to various control parameters may include, but are not limited to, heat source power, additive feed rate(s) (e.g. oxygen, oxidants, steam, etc.), feedstock feed rate(s) (e.g. one or more distinct and/or mixed feeds), gas and/or system pressure/flow regulators (e.g. blowers, relief and/or control valves, flares, etc.), material displacement within the gasifier (e.g. between vertically successive processing regions), and the like, can be executed in a manner whereby one or more process-related characteristics are assessed and optimized according to design and/or downstream specifications.
  • additive feed rate(s) e.g. oxygen, oxidants, steam, etc.
  • feedstock feed rate(s) e.g. one or more distinct and/or mixed feeds
  • gas and/or system pressure/flow regulators e.g. blowers, relief and/or control valves, flares, etc.
  • material displacement within the gasifier e.g. between vertically successive processing regions
  • control system may be configured to monitor operation of the various components of a given system for assuring proper operation, and optionally, for ensuring that the process(es) implemented thereby are within regulatory standards, when such standards apply.
  • control system may further be used in monitoring and controlling the total energetic impact of a given system.
  • a given system may be operated such that an energetic impact thereof is reduced, or again minimized, for example, by optimising one or more of the processes implemented thereby, or again by increasing the recuperation of energy (e.g. waste heat) generated by these processes.
  • the control system may be configured to adjust a composition and/or other characteristics (e.g. temperature, pressure, flow, etc.) of a product gas generated via the controlled process(es) such that such characteristics are not only suitable for downstream use, but also substantially optimised for efficient and/or optimal use.
  • the characteristics of the product gas may be adjusted such that these characteristics are best matched to optimal input characteristics for such engines.
  • the control system may be configured to adjust a given process such that limitations or performance guidelines with regards to reactant and/or product residence times in various components, or with respect to various processes of the overall process are met and/or optimised for.
  • an upstream process rate may be controlled so as to substantially match one or more subsequent downstream processes.
  • the residence time of the material within the gasifier, and/or processing regions thereof may be set and/or dynamically adjusted by a material displacement control module, which may operate independently, cooperatively and/or as a submodule of an overall or global control system, to meet certain preferences and/or requirements of downstream processes and/or applications.
  • a material displacement control module which may operate independently, cooperatively and/or as a submodule of an overall or global control system, to meet certain preferences and/or requirements of downstream processes and/or applications.
  • control system can be adapted for maintaining conditions suitable for local and/or downstream needs, e.g., temperature, feedstock input rate, displacement of material, etc. can be controlled to meet local needs, such as fast processing of waste, and/or to meet downstream needs such as suitable gas composition.
  • control system may, in various embodiments, be adapted for the sequential and/or simultaneous control of various aspects of a given process in a continuous and/or real time manner.
  • control system controls (among other aspects of the process) the input of additives into the gasifier.
  • the off-gases and/or steam can be recycled back into the gasifier as part or whole of an additive stream.
  • the control system may utilize a steam recycling control strategy to determine the addition of the steam.
  • Addition of steam to high temperature areas may have two effects: (a) cools the area due to endothermic gasification reactions with steam, absorbs excess heat and stabilizes the area to avoid melting/slagging from occurring within the gasifier; (b) improves the quality of the gas and helps remove fixed carbon from the solids.
  • Such a control strategy may use either feedback/feed-forward control and may utilize fuzzy logic.
  • the "quality of a gas” is based on the downstream application (e.g. gas engine, chemical production facility etc.) for which the gas is used. Generally if the gas has a very high CO to CO 2 ratio and low H 2 , steam addition from recycling will improve the quality of the gas, resulting in higher heating value and higher H 2 vs CO). This improvement in the CO to H 2 ratio is achieved with steam by moving the water-gas shift reaction equilibrium to produce more H 2 by converting CO to CO 2 and converting H 2 O to H 2 .
  • a feedback control system may utilize temperature measurements made by thermocouples placed at various locations throughout the gasification facility, and particularly in areas where steam may be added. When the temperature gets too high in an area, part of the off-gases and/or steam from the processing regions promoting drying is diverted to that area using either piping to the walls/jacket or through a fluid conduit.
  • control schemes may be automated, and may utilize fuzzy logic to ensure that the steam is applied in the correct amounts and to the correct location within the system for the optimal results.
  • the recycled stream can be heated in a heat exchanger to help improve the reaction rates of the system to produce higher quality gas with less recycling. This approach also helps with pressure drops and other parasitic loads.
  • control system may comprise any type of control system architecture suitable for the application at hand.
  • the control system may comprise a substantially centralized control system, a distributed control system, or a combination thereof.
  • a centralized control system will generally comprise a central controller configured to communicate with various local and/or remote sensing devices and response elements configured to respectively sense various characteristics relevant to the controlled process, and respond thereto via one or more controllable process devices adapted to directly or indirectly affect the controlled process.
  • most computations are implemented centrally via a centralized processor or processors, such that most of the necessary hardware and/or software for implementing control of the process is located in a same location.
  • a distributed control system will generally comprise two or more distributed controllers which may each communicate with respective sensing and response elements for monitoring local and/or regional characteristics, and respond thereto via local and/or regional process devices configured to affect a local process or sub-process. Communication may also take place between distributed controllers via various network configurations, wherein a characteristics sensed via a first controller may be communicated to a second controller for response thereat, wherein such distal response may have an impact on the characteristic sensed at the first location. For example, a characteristic of a downstream product gas may be sensed by a downstream monitoring device, and adjusted by adjusting a control parameter associated with the converter that is controlled by an upstream controller.
  • control hardware and/or software is also distributed between controllers, wherein a same but modularly configured control scheme may be implemented on each controller, or various cooperative modular control schemes may be implemented on respective controllers.
  • control system may be subdivided into separate yet communicatively linked local, regional and/or global control subsystems.
  • Such an architecture could allow a given process, or series of interrelated processes to take place and be controlled locally with minimal interaction with other local control subsystems.
  • a global master control system could then communicate with each respective local control subsystems to direct necessary adjustments to local processes for a global result.
  • control system of the present invention may use any of the above architectures, or any other architecture commonly known in the art, which are considered to be within the general scope and nature of the present disclosure.
  • processes controlled and implemented within the context of the invention may be controlled in a dedicated local environment, with optional external communication to any central and/or remote control system used for related upstream or downstream processes, when applicable.
  • the control system may comprise a sub-component of a regional and/or global control system designed to cooperatively control a regional and/or global process.
  • a modular control system may be designed such that control modules interactively control various sub-components of a system, while providing for inter-modular communications as needed for regional and/or global control.
  • the control system generally comprises one or more central, networked and/or distributed processors, one or more inputs for receiving current sensed characteristics from the various sensing elements, and one or more outputs for communicating new or updated control parameters to the various response elements.
  • the one or more computing platforms of the control system may also comprise one or more local and/or remote computer readable media (e.g. ROM, RAM, removable media, local and/or network access media, etc.) for storing therein various predetermined and/or readjusted control parameters, set or preferred system and process characteristic operating ranges, system monitoring and control software, operational data, and the like.
  • the computing platforms may also have access, either directly or via various data storage devices, to process simulation data and/or system parameter optimization and modeling means.
  • the computing platforms may be equipped with one or more optional graphical user interfaces and input peripherals for providing managerial access to the control system (system upgrades, maintenance, modification, adaptation to new system modules and/or equipment, etc.), as well as various optional output peripherals for communicating data and information with external sources (e.g. modem, network connection, printer, etc.).
  • the processing system and any one of the sub-processing systems can comprise exclusively hardware or any combination of hardware and software. Any of the sub- processing systems can comprise any combination of none or more proportional (P), integral (I) or differential (D) controllers, for example, a P-controller, an I-controller, a PI- controller, a PD controller, a PID controller etc.
  • P proportional
  • I integral
  • D differential
  • a conventional feedback or responsive control system may further be adapted to comprise an adaptive and/or predictive component, wherein response to a given condition may be tailored in accordance with modeled and/or previously monitored reactions to provide a reactive response to a sensed characteristic while limiting potential overshoots in compensatory action.
  • acquired and/or historical data provided for a given system configuration may be used cooperatively to adjust a response to a system and/or process characteristic being sensed to be within a given range from an optimal value for which previous responses have been monitored and adjusted to provide a desired result.
  • Such adaptive and/or predictive control schemes are well known in the art, and as such, are not considered to depart from the general scope and nature of the present disclosure.
  • Sensing elements contemplated within the present context can include, but are not limited to, temperature sensing elements, position sensors, proximity sensors, pile height sensors and means for monitoring gas.
  • the gasifier comprises a temperature sensor array of one or more removable thermocouples.
  • the thermocouples can be strategically placed to monitor temperature at various points within each processing region of the gasifier.
  • Appropriate thermocouples are known in the art and include bare wire thermocouples, surface probes, thermocouple probes including grounded thermocouples, ungrounded thermocouples and exposed thermocouples or combinations thereof.
  • thermocouples are inserted into a processing chamber via a sealed end tube (thermowell) which is then sealed to the chamber's shell, allowing for the use of flexible wire thermocouples which are procured to be longer than the sealing tube so that the junction (the temperature sensing point) of the thermocouple is pressed against the end of the sealed tube to assure accurate and quick response to temperature change.
  • the end of the sealed tube cap can be fitted with a deflector, hi one embodiment, the deflector is a square flat plate, with bent corners that contact the refractory and are in-line with reactant material flow to slip-stream particles over the thermowell.
  • the invention may comprise devices for monitoring the exit of product gas. These may include but are not limited to gas composition monitors and gas flow meters.
  • a gas analyser is provided downstream from the gasifier enabling analysis of the product gas, in this embodiment before homogenization for downstream use, in order to regulate various aspects of the gasification process. For example, when it is determined that the carbon content of the product gas is insufficient, an increase in the high carbon feed rate (e.g. plastics in feedstock input), when available, is increased accordingly, hi another example, when the heating value of the product gas (e.g. high heating value, low heating value) is determined to be too low, the feed rate and additive input ratio may be adjusted, or again, the ratio of high carbon feed rate to primary feed rate may be adjusted.
  • the high carbon feed rate e.g. plastics in feedstock input
  • a gas flow or pressure monitor may be used in an embodiment where a selected downstream application is adversely affected by variations and/or absolute fluctuations in gas flow/pressure, hi response to a sensed variation in product gas pressure, for example, additive input feed rates may be adjusted, thereby adjusting the gas output of the gasifier. hi response to such adjustment, other process characteristics, such as feedstock input rate, HCF input rate, process temperature, etc. may also be adjusted to rebalance the process and substantially maintain desired output characteristics.
  • the amount of air injected can be optimized to maximize efficiency and minimize undesirable process characteristics and products including slagging of ash, combustion, poor gas heating value, excessive particulate matter and dioxin/furan formation thereby meeting or bettering local emission standards.
  • Such measurements can be taken during initial start-up or initial testing of the gasifier, periodically or continually during operation of the gasifier and may optionally be taken in real time.
  • the gasifier can optionally comprise a pressure sensor or monitor within the gasifier.
  • the gasifier can further comprise level switches or monitors to assess pile height.
  • level switches or monitors to assess pile height.
  • Appropriate level switches, sensors and monitors are known in the art.
  • the level instrumentation comprises point-source level switches
  • the level switches are microwave devices with an emitter on one side of the processing chamber and a receiver on the other side, which detects either presence or absence of reactant material at that point inside the processing chamber.
  • the gasifier further comprises proximity or position sensors.
  • Response elements contemplated within the present context can include, but are not limited to, various control elements operatively coupled to process-related devices configured to affect a given process by adjustment of a given control parameter related thereto.
  • process devices operable within the present context via one or more response elements may include, but are not limited to elements controlling chamber heating, elements controlling the input of additives, feedstocks and other process constituents, and elements of the material displacement control module, to name a few.
  • the material displacement control module may be used in such embodiments to regulate the pile height inside a given chamber of the gasifier.
  • Low levels of the feedstock pile can result in fluidization of the reactant material from injection of pre-heated air while high levels of the feedstock pile can result in poor temperature distribution through the reactant material pile due to restricted airflow. Therefore, a level control system with the use of a series of level switches may be used to maintain stable pile height inside the gasifier. Maintaining stable level also maintains consistent residence time in the gasifier.
  • the material displacement control module may be used as necessary to ensure that pile height is controlled at the desired level.
  • the material displacement control module comprise pusher rams
  • the pusher rams move in a series of programmed step of which there may exist a number of control parameters that may include, but are not limited to: specific movement sequence, speed, distance, and sequence frequency.
  • the pusher rams move out to a set point distance, or until a controlling level switch is tripped; either at the same time or in a pre-determined sequence.
  • the level switch control action can be based on a single switch, tripping either empty or full, or may require multiple switches tripping, empty or full, or any combination thereof.
  • the pusher rams move back to end the cycle, and the process is repeated. There is an optional delay between cycles as required by the process and residence time requirements of the gasifier.
  • the height of the reactant material pile in the processing chamber is a function of the input feed-rate and the pusher ram motion.
  • the processing chamber has three processing regions and the material displacement control module has three pusher rams with one pusher ram dedicated to each of the three processing regions for the movement of reactant material/residue out of that processing region.
  • the third pusher ram controlling the movement of the residue out of the third processing region of the processing chamber sets the throughput by moving at a fixed stroke length and frequency to discharge the residue out of the processing chamber.
  • the second pusher ram follows and moves as far as necessary to push reactant material onto the third processing region and change the third processing region's start-of-stage level switch state to "full”.
  • the first pusher ram follows and moves as far as necessary to push reactant material onto the second processing region and change the second processing region's start-of-stage level switch state to "full”. All three pusher rams are then withdrawn simultaneously, and a scheduled delay is executed before the entire sequence is repeated. Additional configuration may be used to limit the change in consecutive stroke lengths to less than that called for by the level switches to avoid excess ram-induced disturbances.
  • the pusher rams will always need to be moved fairly frequently in order to prevent over-temperature conditions at the bottom of the processing chamber. Appropriate pusher ram sequences can be readily developed for other embodiments of the gasifier and are considered to be within the scope of this invention.
  • different material movement units e.g. mechanisms, devices, etc.
  • control parameters of the material movement control module at least partially influenced by pile height readings.
  • rotary arm configurations controlling movement of material may be used in step to adjust pile heights within respective processing regions, as can others of the above examples, as will be apparent to the person of skill in the art.
  • the control system may be further configured to assess optimal processing characteristics, taking into account optimal residence times of material within each region, pile height restrictions and favourable conditions, as well as other characteristics as described herein for a given process result.
  • control system may further provide for the control of temperature within the gasifier.
  • the feedstock should be kept at as high a temperature as possible, for as long as possible.
  • the material begins to melt and agglomerate forming 'clinkers' which affects the gasification performance in multiple ways: (1) it reduces the available surface area and hence the conversion efficiency; (2) it causes the airflow in the reactant material pile to divert around the chunks of agglomeration, aggravating the temperature issues and further accelerating the agglomeration process; (3) it interferes with the normal operation of the material displacement control module; and (4) it can jam the residue removal mechanisms thus potentially causing a system shut down.
  • the temperatures in the gasifier and temperature distribution through the pile can be stabilized and controlled.
  • Stable temperature distribution throughout the reactant material pile may also be used to prevent a second kind of agglomeration, in which plastic melts and acts as a binder for the rest of the reactant material.
  • temperature control within the pile is achieved by changing the flow of process air into a given region (ie. more or less combustion).
  • the process air flow provided to each processing region in the gasifier may be adjusted by the control system to stabilize temperatures at that region.
  • Temperature control utilizing displacement units may also be used to break up hot spots and to avoid bridging.
  • the air flow at each processing region is pre-set to maintain substantially constant temperature ranges and ratios between processing regions.
  • air input ratios may be varied dynamically to adjust temperatures and processes occurring within each processing region of the gasifier and/or within the GRS.
  • the means for controlling the reaction conditions to manage the chemistry and energetics of the gasification of a feedstock comprise a main integrated processor and a series of sensors for monitoring the state of the system and control systems for controlling various operational parameters, for example, the rate of addition of feedstock and/or additives, as well as operating conditions, such as pressure in the processing chamber.
  • the main integrated processor receives data obtained from sensors relating to current states of the gasification reaction, and processes these data to generate an appropriate set of output instructions to manage the chemistry and energetics of the conversion reaction, whereby the optimal reaction set point is maintained.
  • the conditions within the gasifier can be adjusted either manually or automatically.
  • the gasifier can be regulated by a series of on/off switches and instruments.
  • the computation means can optionally include various output means. Different types of control schemes, outlined below, can be used.
  • Fuzzy logic control as well as other types of control can equally be used in feed forward and feedback control schemes. These types of control can substantially deviate from classical P, I, D combination control in the ways the reaction dynamics are modeled and simulated to predict how to change input variables or input parameters to affect a desired outcome. Fuzzy logic control usually only requires a vague or empirical description of the reaction dynamics (in general the system dynamics) or the operating conditions of the system. Aspects and implementation considerations of fuzzy logic and other types of control are well known to a person skilled in the art.
  • Feed forward control processes input parameters to influence, without monitoring, control variables and control parameters.
  • a gasification facility can use feed forward control for a number of control parameters such as the amount of power supplied to one of the one or more plasma torches in the gas reformulating chamber (GRS).
  • the power output of the arcs of plasma torches can be controlled in a variety of different ways, for example, by pulse modulating the electrical current which is supplied to the torch to maintain the arc, varying the distance between the electrodes, limiting the torch current, or affecting the composition, orientation or position of the plasma.
  • the rate of supply of additives to the gasifiers and/or the gas reformulator in a gaseous or liquid form or a pulverized form which can be sprayed or otherwise injected via nozzles can be controlled with certain control elements in a feed forward way. Effective control of an additive's temperature or pressure, however, may require monitoring and closed loop feed back control.
  • a control parameter or control variable is compared to a desired value.
  • a control signal is determined based on the deviation between the two values and provided to a control element in order to reduce the deviation. For example, when the output gas exceeds a predetermined H 2 : CO ratio, a feedback control system can determine an appropriate adjustment to one of the input variables, such as increasing the amount of additive air to return the H 2 : CO ratio to the desired value.
  • the delay time to affect a change to a control parameter or control variable is sometime called loop time.
  • the loop time for example, to adjust the power of the plasma arc, air or steam flow rate, can amount to 30 to 60 seconds.
  • Feed back control may be used for all control variables and control parameters which use direct monitoring or where a model prediction is satisfactory.
  • control variables and control parameters of the gasifier that lend themselves towards use in a feedback control scheme.
  • Feedback schemes can be effectively implemented in aspects of the control system for those control variables or control parameters which can be directly sensed and controlled and whose control does not, for practical purposes, depend upon other control variables or control parameters.
  • Modulated plants are facilities where each function block is a pre-built module. Modules are built and tested in a factory setting and then sent out to the facility site. They include all the equipment and controls needed to be functional. Modules include Gasifier Block, Gas Conditioning System Block, Power Block, etc. On-site, these modules would only need to be connected to other modules and the control system to be ready for plant's commissioning. This design allows for shorter construction time and economic savings due to reduced on-site construction costs. There are different types of modular plants set-ups. Larger modular plants incorporate a "backbone 1 piping design where most of the piping is bundled together to allow for smaller footprint.
  • a modular design allows this technology to replace or add modules to the plant to increase its capacity, rather then building a second plant. Modules and modular plants can be relocated to other sites where they can be quickly integrated into a new location.
  • Modules can also be placed in series or parallel. Here similar tasked equipment can share the load or successively provide processing to the product stream. For example, product gas output from the plurality of gasifiers are not combined to pass through a single GRS and GCS but is split up into two parallel streams, each with its own GRS and GCS.
  • the gasification system as comprising of the function blocks A, B & C and the GCS, it can be further subdivided into other smaller function blocks.
  • the function block A, B & C could represent the drying region, volatilization region and the carbon conversion region respectively such that a single gasifier can be formed by the combination of these function blocks.
  • the trains can be combined in a larger family of schemes depending on where the combination of the trains is effected.

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Abstract

La présente invention porte sur un gazéifieur comprenant un ou plusieurs conduits de fluide pour convertir une charge d'alimentation carbonée en un gaz de dégagement et une matière solide résiduelle. Le gazéifieur comprend une chambre de traitement à revêtement réfractaire ayant un ou plusieurs conduits de fluide situés dans celle-ci pour faciliter le passage d'une matière fluide telle qu'un gaz à l'intérieur de et/ou à l'extérieur de la chambre. Par exemple, un conduit facilite l'entrée d'additifs de traitement et/ou la sortie de vapeur et/ou de gaz de dégagement de la chambre de traitement. Le gazéifieur comprend une ou plusieurs entrées pour recevoir une charge d'alimentation, une ou plusieurs sorties de résidu et des moyens de chauffage pour faciliter le traitement de conversion et un système de commande pour commander divers aspects du traitement de gazéification. Facultativement, le gazéifieur peut être configuré pour recycler de la vapeur et/ou un gaz de dégagement et/ou une chaleur recyclée à nouveau à l'intérieur de la chambre de traitement. Facultativement, le gazéifieur peut en outre comprendre un ou plusieurs modules de commande de déplacement de matière et des moyens de mélange.
PCT/CA2008/001301 2007-07-17 2008-07-17 Gazéifieur comprenant un ou plusieurs conduits de fluide WO2009009891A1 (fr)

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CA2731115A CA2731115A1 (fr) 2007-07-17 2008-07-17 Gazeifieur comprenant un ou plusieurs conduits de fluide
US12/669,431 US20100154304A1 (en) 2007-07-17 2008-07-17 Gasifier comprising one or more fluid conduits

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