U.S. patent application number 11/757189 was filed with the patent office on 2008-06-05 for production of synthetic gas from organic waste.
This patent application is currently assigned to INTERNATIONAL ENVIRONMENTAL SOLUTIONS CORPORATION. Invention is credited to Cameron Cole, Toby L. Cole, Michael Scott Sorrell, Raul de al Torres, Dan Watts.
Application Number | 20080127867 11/757189 |
Document ID | / |
Family ID | 40130610 |
Filed Date | 2008-06-05 |
United States Patent
Application |
20080127867 |
Kind Code |
A1 |
Cole; Cameron ; et
al. |
June 5, 2008 |
Production of Synthetic Gas From Organic Waste
Abstract
A pyrolysis device has a pyrolyzer (retort) and a thermal
oxidizer, each with its own burner, but coupled so that the burner
of the pyrolyzer can be down-regulated as heat from the thermal
oxidizer is used to hear the pyrolyzer. One or more automatic
controllers preferably adjust a burn rate of the extrinsic gas by
the first burner as a function of a rate at which heat is
transferred from the thermal oxidizer to the pyrolyzer. In
preferred embodiments, the burn rate of the extrinsic gas can be
adjusted to .ltoreq.50%, .ltoreq.30% or even lower relative to a
base rate that would be required to pyrolyze the waste without the
heat thermal oxidizer.
Inventors: |
Cole; Cameron; (Rainbow,
CA) ; Cole; Toby L.; (Temecula, CA) ; Watts;
Dan; (Surfside, CA) ; Torres; Raul de al;
(Bell Gardens, CA) ; Sorrell; Michael Scott; (San
Jacinto, CA) |
Correspondence
Address: |
FISH & ASSOCIATES, PC;ROBERT D. FISH
2603 Main Street, Suite 1050
Irvine
CA
92614-6232
US
|
Assignee: |
INTERNATIONAL ENVIRONMENTAL
SOLUTIONS CORPORATION
Romoland
CA
|
Family ID: |
40130610 |
Appl. No.: |
11/757189 |
Filed: |
June 1, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60810382 |
Jun 1, 2006 |
|
|
|
Current U.S.
Class: |
110/230 |
Current CPC
Class: |
F23G 5/027 20130101;
F23G 5/12 20130101; F23G 5/16 20130101; F23G 2201/303 20130101 |
Class at
Publication: |
110/230 |
International
Class: |
F23G 5/12 20060101
F23G005/12 |
Claims
1. A device for pyrolytically treating a waste, comprising: a
pyrolyzer and a thermal oxidizer; a first burner that primarily
heats the pyrolyzer to produce a synthetic gas from the waste; a
second burner that primarily assists in combusting the synthetic
gas in the thermal oxidizer; and a heat transfer component that
carries heat from the thermal oxidizer to the pyrolyzer.
2. The device of claim 1, wherein the first burner receives a
supply of extrinsic gas.
3. The device of claim 2, further comprising a controller that
automatically adjusts a burn rate of the extrinsic gas by the first
burner as a function of a rate at which heat is transferred from
the thermal oxidizer to the pyrolyzer.
4. The device of claim 2, further comprising a controller that
automatically adjusts a burn rate of the extrinsic gas to below 50%
of a base rate that would be required to pyrolyze the waste without
the heat thermal oxidizer.
5. The device of claim 2, further comprising a controller that
automatically adjusts a burn rate of the extrinsic gas to below 30%
of a base rate that would be required to pyrolyze the waste without
the heat thermal oxidizer.
6. The device of claim 2, further comprising a controller that
automatically adjusts relative amounts of the extrinsic and syn
gasses combusted by the first burner as a function of a
characteristic of the syn gas.
7. The device of claim 1, further comprising a line that carries a
portion of the syn gas to the first burner.
Description
PRIORITY CLAIM
[0001] This application claims priority to provisional application
Ser. No. 60/810382 filed Jun. 1, 2006.
FIELD OF THE INVENTION
[0002] The field of the invention is pyrolysis.
BACKGROUND
[0003] Pyrolysis of wastes often produces combustible gases (i.e.,
synthetic or syn gases) that can be burned in a thermal oxidizer to
produce heat, and ultimately to generate electricity. US619214 to
Walker et al. (September '03) and U.S. Pat. No. 7,044,069 to Cole
et al. May 2006) teach that some of the heat produced by oxidation
of the syn gas can also be used for other purposes, including
heating of the reaction chamber of the pyrolytic converter (also
referred to herein as the pyrolyzer), and drying of the waste prior
to pyrolysis.
[0004] Various other improvements are described in patents and
applications of the same family, including US700551 (February '06),
U.S. Pat. No. 6,988,453 (January 2006), US2005/0039651 (February
2005), U.S. Pat. No. 7,191,714 (March 2007), and US 11/286552
(filed Nov. 22, 2005). These and all other extrinsic materials
referenced herein are incorporated by reference in their entirety.
Where a definition or use of a term in an incorporated reference is
inconsistent or contrary to the definition of that term provided
herein, the definition of that term provided herein applies and the
definition of that term in the reference does not apply.
[0005] Significantly, both Walker '213 and Cole '069 patents
contemplate that all of the heat used to pyrolyze the waste comes
from the thermal oxidizer. There is no separate burner to provide
heat directly to the pyrolyzer. The Walker '213 design splits the
thermal oxidizer into two sections, each with its own burners. The
burners of the first section are used to heat up the pyrolyzer upon
cold start, and then to assist in burning the syn gas once
pyrolysis is underway. The Cole '069 design shunts the combustion
gasses from the thermal oxidizer into the outer chambers of dual
pyrolyzers. Both designs turn out to be problematic because of
difficulties in implementation.
[0006] What is needed are systems and methods in which the
pyrolyzer has its own burner(s), which can be controlled
independently of the thermal oxidizer, but which can be
down-regulated as heat from the thermal oxidizer is used to hear
the pyrolyzer.
SUMMARY OF THE INVENTION
[0007] The present invention provides systems, methods and devices
in which a pyrolyzer has its own burner(s), which can be controlled
independently of the thermal oxidizer, but which can be
down-regulated as heat from the thermal oxidizer is used to hear
the pyrolyzer.
[0008] In preferred embodiments of the apparatus, a device for
pyrolytically treating a waste comprises a pyrolyzer and a thermal
oxidizer, a first burner that primarily heats the pyrolyzer to
produce a synthetic gas from the waste, a second burner that
primarily assists in combusting the synthetic gas in the thermal
oxidizer; and a heat transfer component that carries heat from the
thermal oxidizer to the pyrolyzer. The first and second burners can
advantageously receive a supply of extrinsic gas, such as from a
natural gas line.
[0009] One or more automatic controllers preferably adjust a burn
rate of the extrinsic gas by the first burner as a function of a
rate at which heat is transferred from the thermal oxidizer to the
pyrolyzer. In preferred embodiments, the burn rate of the extrinsic
gas can be adjusted to .ltoreq.50%, .ltoreq.30% or even lower
relative to a base rate that would be required to pyrolyze the
waste without the heat thermal oxidizer.
[0010] It is also contemplated that a line can carry a portion of
the un-combusted or partially combusted syn gas to be burned along
with the extrinsic gas at the first burner, which process can also
be under the control of an automatic controller.
[0011] Various objects, features, aspects and advantages of the
present invention will become more apparent from the following
detailed description of preferred embodiments of the invention,
along with the accompanying drawings in which like numerals
represent like components.
BRIEF DESCRIPTION OF THE DRAWING
[0012] FIG. 1 is a perspective view of a prior art pyrolysis system
including a retort and a thermal oxidizer.
[0013] FIG. 2 is a perspective view of a novel pyrolysis system in
which combustion gas from the thermal oxidizer is used to assist in
heating the pyrolyzer.
[0014] FIG. 3 is a perspective view of a novel pyrolysis system in
which syn gas is being fed to the burner of the pyrolyzer.
[0015] FIG. 4 is a perspective view of a novel two level pyrolysis
system in which combustion gas from the thermal oxidizer is used to
assist in heating the pyrolyzer.
DETAILED DESCRIPTION
[0016] In FIG. 1, a prior art pyrolytic device 100 includes an
inner chamber 112 and an outer chamber 113. A rotating drive 114
carries waste 111 through the inner chamber 112, where the waste is
subjected to heat to produce a combustible synthetic ("syn") gas
116 and pyrolyzed solids 119. The pyrolyzing heat is provided by a
burner 120, which burns natural or other extrinsic gas 117 and
releases the exhaust into outer chamber 113. Syn gas 116 generated
by the process travels to the thermal oxidizer ("after burner")
120, where it is combined with air, and combusted along with
additional extrinsic gas 127. Combusted gas exhaust from the
thermal oxidizer 120 is sent to the boiler of a power plant 130 to
produce steam and ultimately, electricity. Details are provided in
the patents and applications incorporated herein by reference.
[0017] In FIG. 2, a novel pyrolytic device 200 includes all the
listed components discussed above for device 100. In addition,
device 200 includes line 142 that carries combusted or
semi-combusted gasses from the thermal oxidizer 120 to the outer
chamber 113 of the pyrolyzer 110, where they provide heat to
pyrolyze the waste 111. Exhaust from the pyrolyzer 110 can be used
to dry waste 111 before it is fed into the pyrolyzer, utilized in
operating the power plant, or utilized for any other purpose.
Although not preferred, the exhaust could also be vented. Lines
carrying the exhaust are not shown.
[0018] Once syn gas is being produced in good quantity, and
depending upon selected operating parameters, the heat provided via
line 142 can provide a majority or even all of the heat needed to
pyrolyze the waste 111. In especially preferred embodiments, the
balance of heat provided by combusting the extrinsic gas and the
heat being provided via line 142 is automatically controlled by
controller 150. For example, if the natural gas or other extrinsic
gas is being procured at very low cost, or if energy production is
being maximized, the amount of heat being siphoned off via line 142
could be low or even zero. On the other hand, if the extrinsic gas
is relatively expensive, or if energy production is not being
maximized, or perhaps more heat is being generated that can be
effectively used in the power plant, relatively more heat could be
siphoned off via line 142. It is contemplated that the controller
could automatically adjust a burn rate of the extrinsic gas to
below 50% of a base rate that would be required to pyrolyze the
waste without the heat thermal oxidizer. That percentage could be
cut further to below 30%, below 25%, below 20% and even down to
zero for a period of time.
[0019] It is also contemplated that the controller could
automatically adjusts relative amounts of the extrinsic and syn
gasses as a function of a characteristic of the syn gas being
produced. Suitable characteristics upon which to base the
adjustments include quantity of syn gas, and relative amounts of
combustible and non-combustible constituents of the syn gas.
[0020] Given this disclosure, development and appreciation of
contemplated electronic and other controls are well within the
skill of those in the art, including for example Johnson
Controls.TM..
[0021] In FIG. 3, device 300 is similar to device 200 except that
here some of the syn gas is ported to the burner 116 of the
pyrolyzer 110 via line 144. At present is a less preferred
embodiment, and would generally make sense where the syn gas being
ported has not yet been fully combusted.
[0022] In FIG. 4, device 400 is again similar to device 200. One
major difference is that here the pyrolyzer 110 and thermal
oxidizer 120 are vertically disposed relative to one another rather
than horizontally disposed. Among other things, this configuration
can provide much greater efficiency in terms of land usage. In this
particular instance, heat (in the form of hot combusted or
semi-combusted gasses) are ported from the thermal oxidizer 120 to
the pyrolyzer 110 via line 146.
[0023] It should be appreciated that in each of FIGS. 2-4, burner
116 is used primarily to heat the pyrolyzer 110, to produce a
synthetic gas from the waste 111. Similarly, in each of FIGS. 2-4,
the second burner 126 primarily assists in combusting the synthetic
gas in the thermal oxidizer 120. As used herein, the term
"primarily" refers to functions during normal steady-state
operation, as opposed for example to start-up or shutdown
procedures. In contrast, the primary function of burner 66 in U.S.
Pat. No. 6,619,214 is to provide heat to the thermal oxidizer 26,
not to heat the pyrolytic converter 24.
[0024] It should also be apparent to those skilled in the art that
many more modifications besides those already described are
possible without departing from the inventive concepts herein.
Moreover, in interpreting the disclosure, all terms should be
interpreted in the broadest possible manner consistent with the
context. In particular, the terms "comprises" and "comprising"
should be interpreted as referring to elements, components, or
steps in a non-exclusive manner, indicating that the referenced
elements, components, or steps could be present, or utilized, or
combined with other elements, components, or steps that are not
expressly referenced. Where the specification claims refers to at
least one of something selected from the group consisting of A, B,
C . . . and N, the text should be interpreted as requiring only one
element from the group, not A plus N, or B plus N, etc.
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