U.S. patent application number 13/841559 was filed with the patent office on 2013-09-19 for process and system for production of synthesis gas.
This patent application is currently assigned to THERMO TECHNOLOGIES, LLC. The applicant listed for this patent is THERMO TECHNOLOGIES, LLC. Invention is credited to Grigori A. Abramov, Dennis E.J. Johnson, Richard A. Kleinke, Marcus A. Wiley.
Application Number | 20130240344 13/841559 |
Document ID | / |
Family ID | 38610370 |
Filed Date | 2013-09-19 |
United States Patent
Application |
20130240344 |
Kind Code |
A1 |
Johnson; Dennis E.J. ; et
al. |
September 19, 2013 |
Process and System for Production of Synthesis Gas
Abstract
Methods and apparatus may permit the generation of consistent
output synthesis gas from highly variable input feedstock solids
carbonaceous materials. A stoichiometric objectivistic chemic
environment may be established to stoichiometrically control carbon
content in a solid carbonaceous materials gasifier system.
Processing of carbonaceous materials may include dominative
pyrolytic decomposition and multiple coil carbonaceous reformation.
Dynamically adjustable process determinative parameters may be
utilized to refine processing, including process utilization of
negatively electrostatically enhanced water species, process
utilization of flue gas, and adjustment of process flow rate
characteristics. Recycling may be employed for internal reuse of
process materials, including recycled negatively electrostatically
enhanced water species, recycled flue gas, and recycled
contaminants. Synthesis gas generation may involve predetermining a
desired synthesis gas for output and creating high yields of such a
predetermined desired synthesis gas.
Inventors: |
Johnson; Dennis E.J.;
(Colorado Springs, CO) ; Abramov; Grigori A.;
(Littleton, CO) ; Kleinke; Richard A.; (Commerce
City, CO) ; Wiley; Marcus A.; (Highlands Ranch,
CO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
THERMO TECHNOLOGIES, LLC |
Centennial |
CO |
US |
|
|
Assignee: |
THERMO TECHNOLOGIES, LLC
Centennial
CO
|
Family ID: |
38610370 |
Appl. No.: |
13/841559 |
Filed: |
March 15, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13335683 |
Dec 22, 2011 |
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13841559 |
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13110784 |
May 18, 2011 |
8197698 |
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13335683 |
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12246395 |
Oct 6, 2008 |
7968006 |
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13110784 |
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PCT/US2007/066466 |
Apr 11, 2007 |
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12246395 |
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12296202 |
Oct 6, 2008 |
7857995 |
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PCT/US2007/066466 |
Apr 11, 2007 |
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12246395 |
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60791401 |
Apr 11, 2006 |
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60791401 |
Apr 11, 2006 |
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Current U.S.
Class: |
201/32 ; 202/106;
202/108; 202/110; 202/117 |
Current CPC
Class: |
C10J 2300/093 20130101;
C02F 1/32 20130101; C10J 2300/0943 20130101; C10J 2300/0946
20130101; C10J 2300/0916 20130101; C10J 2300/1215 20130101; C10J
2300/0903 20130101; Y02E 50/30 20130101; C10B 1/10 20130101; C10J
3/66 20130101; Y02P 20/145 20151101; Y02E 20/18 20130101; C10K
1/101 20130101 |
Class at
Publication: |
201/32 ; 202/117;
202/110; 202/108; 202/106 |
International
Class: |
C10B 1/10 20060101
C10B001/10 |
Claims
1-50. (canceled)
51. A pyrolysis and gasification system, comprising: a feedstock
hopper that receives a carbonaceous feedstock; and a tapered
pyrolysis drum that rotates about an axis and drives off carbon
based volatiles contained in the carbonaceous feedstock.
52. The system of claim 51, the pyrolysis and gasification system
increases heat transfer to the carbonaceous feedstock through use
of internal flights within the tapered pyrolysis drum.
53. The system of claim 51, further comprising a first
counter-operating pressure valve and a second counter-operating
pressure valve.
54. The system of claim 53, the first counter-operating pressure
valve and the second counter-operating pressure valve maintain a
pressure of at least 50 pounds per square inch (psi) within the
pyrolysis and gasification system.
55. The system of claim 53, the first counter-operating pressure
valve and the second counter-operating pressure valve maintain a
pressure of at least 250 pounds per square inch (psi) within the
pyrolysis and gasification system.
56. The system of claim 53, further comprising an airlock vessel
disposed between the first counter-operating pressure valve and the
second counter-operating pressure valve.
57. The system of claim 56, the airlock vessel holds a charge of
feedstock received from the feedstock hopper.
58. The system of claim 56, the airlock vessel draws in a vacuum
that evacuates oxygen introduced into the airlock vessel when
feedstock is introduced into the airlock vessel.
59. The system of claim 58, the vacuum is drawn through a venturi
on steam generated or cooling water loops.
60. The system of claim 53, further comprising an accumulation
chamber located after the second counter-operating pressure
valve.
61. The system of claim 60, the accumulation chamber includes a
plunger/auger that advances a charge of feedstock into the tapered
pyrolysis drum.
62. The system of claim 63, further comprises a cooling jacket that
surrounds a pipe connecting the second counter-operating pressure
valve and an accumulation chamber.
63. The system of claim 62, the cooling jacket utilizes cooling
water passed through the cooling jacket to dissipate heat or
prevent the second counter-operating pressure valve from
overheating.
64. The system of claim 51, the tapered pyrolysis drum is connected
to an accumulation chamber via a mechanical seal.
65. The system of claim 64, superheated steam is introduced into
the accumulation chamber via a port in the accumulation
chamber.
66. The system of claim 65, the superheated steam is heated to at
least 1750 .degree. F.
67. The system of claim 51, the tapered pyrolysis drum includes a
neck that protrudes beyond a refractory lined enclosure.
68. The system of claim 67, the neck rests on a load bearing
roller.
69. The system of claim 68, a cam follower bearing is located
outside the refractory lined enclosure and is disposed
perpendicular to the load bearing roller.
70. The system of claim 69, the cam follower bearing restricts
movement or direct linear growth of the tapered pyrolysis drum in
one direction.
71. The system of claim 67, the tapered pyrolysis drum enclosed
within the refractory line enclosure.
72. The system of claim 67, the refractory lined enclosure includes
at least one burner that provides thermal energy to the pyrolysis
and gasification system.
73. The system of claim 67, the refractory lined enclosure
constructed to sustain a pressure of at least 50 psi, creating a
pressure over pressure environment within the tapered pyrolysis
drum.
74. The system of claim 67, the refractory lined enclosure
fabricated to maintain pressured of at least 15 psi or less than
49.9 psi, creating a partial pressure over pressure environment
within the tapered pyrolysis drum.
75. The system of claim 74, the partial pressure over pressure
environment within the tapered pyrolysis drum established by a
compressor or a fan employed to build up pressure.
76. The system of claim 74, the partial pressure over pressure
environment within the tapered pyrolysis drum established by
siphoning off exhaust gas from the refractory lined enclosure and
directing the exhaust gas to a gas turbine to create shaft
horsepower.
77. The system of claim 76, the shaft horsepower utilized to spin a
device that compresses ambient air or combustion air, wherein the
compressed ambient air or combustion air is fed back to the
refractory lined enclosure to build up or sustain the partial
pressure over pressure environment established in the tapered
pyrolysis drum.
78. The system of claim 67, the refractory lined enclosure
constructed to maintain a pressure of at least 14.5 psi, wherein
the refractory lined enclosure is constructed of mild steel.
79. The system of claim 67, the refractory lined enclosure is
manufactured to operate at atmospheric pressure.
80. The system of claim 67, heat vented from the refractory line
enclosure is employed for steam generation or power production.
81. The system of claim 51, a mechanical seal is utilized between
the tapered pyrolysis drum and stationary portions of the pyrolysis
and gasification system.
82. The system of claim 81, the mechanical seal operates to
maintain a working pressure within the tapered pyrolysis drum.
83. The system of claim 51, the tapered pyrolysis drum rotated
about an axis by an electric motor connected to a chain and
sprocket.
84. The system of claim 51, the tapered pyrolysis drum conveys
carbonaceous feedstock from an input end to a discharge end of the
tapered pyrolysis drum via internal flights.
85. The system of claim 51, the tapered pyrolysis drum is
constructed to ensure that no shelf is created when a diameter of
the tapered pyrolysis drum constricts back to an exit gas pipe
size.
86. The system of claim 51, fully pyrolyzed or partially pyrolyzed
carbonaceous feedstock exits from a discharge end of the tapered
pyrolysis drum at a temperature of more than 1450 .degree. F. and
less than 1700 .degree. F.
87. The system of claim 86, the discharge end includes a neck that
rests on a load bearing roller, the neck is connected to a
stationary piece of the gasification and pyrolysis system through a
mechanical seal located external to a refractory lined vessel, the
neck rotatable around an axis on the load bearing roller.
88. The system of claim 87, product gas exits from the tapered
pyrolysis drum into a steam reformer.
89. The system of claim 87, partially pyrolyzed carbonaceous
feedstock transitions via an auger to a secondary solids reactor,
the secondary solids reactor employed to complete conversion of the
partially pyrolyzed carbonaceous feedstock into syngas.
90. The system of claim 89, further comprising a selective
particulate entrapment component that employs a venturi placed
between the tapered pyrolysis drum and a secondary solids reactor,
wherein the venturi captures particles below a specified micro size
in an entrained flow of gas and steam entering a reforming
reactor.
91. An apparatus operable in a carbonaceous gasification
environment, comprising: a hopper that supplies a carbonaceous
feedstock through an airlock vessel that removes entrapped air from
the carbonaceous feedstock; and a tapered pyrolysis drum that
receives the carbonaceous feedstock from the airlock vessel, the
tapered pyrolysis drum includes an internal flight that increases
heat transfer to the carbonaceous feedstock.
92. A method, comprising: introducing feedstock material to a
charge end of a tapered pyrolysis drum; rotating the tapered
pyrolysis drum to advance the feedstock material from the charge
end of the tapered pyrolysis drum to a discharge end of the tapered
pyrolysis drum; heating the feedstock within the tapered pyrolysis
drum, wherein a degree of heat applied at the charge end of the
tapered pyrolysis drum is less than the degree of heat applied at
the discharge end of the tapered pyrolysis drum; and evacuating
from the discharge end of the tapered pyrolysis drum product gas,
and fully pyrolyzed, or partially pyrolyzed, feedstock material.
Description
[0001] This application is a continuation of, and claims benefit of
and priority to, U.S. patent application Ser. No. 13/335,683, filed
Dec. 22, 2011 (published as Publication No. US 2012/0096768 A1 on
Apr. 26, 2012), which is a continuation of, and claims benefit of
and priority to, U.S. patent application Ser. No. 13/110,784, filed
May 18, 2011 (published as Publication No. US 2011/0220584 A1 on
Sep. 15, 2011), which is a continuation of, and claims benefit of
and priority to, U.S. patent application Ser. No. 12/246,395, filed
Oct. 6, 2008 (published as Publication No. US 2009/0126270 A1 on
May 21, 2009 and issued on Jun. 28, 2011 as U.S. Pat. No.
7,968,006), which itself is: (a) a continuation of International
Patent Application No. PCT/US2007/066466, filed Apr. 11, 2007
(published as Publication No. WO 2007/121268 on Oct. 25, 2007),
which claims priority to and the benefit of U.S. Provisional
Application No. 60/791,401, filed Apr. 11, 2006; and (b) a
continuation of U.S. patent application Ser. No. 12/296,202, filed
Oct. 6, 2008 (published as Publication No. US 2009/0126276 A1 on
May 21, 2009 and issued on Dec. 28, 2010 as U.S. Pat. No.
7,857,995), which itself is the National Stage of International
Patent Application No. PCT/US2007/066466, filed Apr. 11, 2007
(published as Publication No. WO 2007/121268 on Oct. 25, 2007),
said International Patent Application claiming priority to and the
benefit of U.S. Provisional Application No. 60/791,401, filed Apr.
11, 2006, each said application hereby incorporated herein by
reference in its entirety.
TECHNICAL FIELD
[0002] The inventive technology described herein relates to
gasifier systems utilizing solid carbonaceous materials to generate
synthesis gases. More specifically, such gasifier systems may be
configured to utilize one or more of a variety of process control
parameters, perhaps singly or in combinations, to achieve high
degrees of efficiency and control in such synthesis gas generation.
The inventive technology may be particularly suited to receive a
great variety of solid carbonaceous materials as feedstock for the
gasifier system and to generate synthesis gases of variable types
suitable for a great variety of subsequent applications.
BACKGROUND
[0003] Pyrolysis, or controlled heating of feedstock in the absence
of oxygen, resulting in thermal decomposition of the feedstock fuel
into volatile gases and solid carbon material by-product, was first
practiced on a commercial scale in 1812, when a city gas company in
London started the production of town gas applications.
[0004] The first commercial gasifier (updraft type) for continuous
gasification of solid fuels, representing an air-blown process, was
installed in 1839 producing what is known as "producer gas"
combustion type gasifiers. They were further developed for
different input fuel feedstocks and were in widespread use in
specific industrial power and heat applications throughout the late
1800's and into the mid-1920's, when petroleum fueled systems
gradually took over the producer gas fuel markets.
[0005] Between 1920 and 1940, small and compact gasifier systems
for automotive applications were developed in Europe. During the
Second World War, perhaps tens of thousands of these combustion
type gasifiers were used in Europe and across other scattered
market applications. Shortly after the War most gasifiers were
decommissioned because of widespread availability of commercial
gasoline and diesel fuels.
[0006] Gasification emphasis again came to the forefront due to the
energy crisis of the 1970's. Gasifier technology was perceived as a
relatively cheap alternative for small-scale industrial and utility
power generation, especially when sufficient sustainable biomass
resources were available. By the beginning of the 1980's nearly a
dozen (mainly European) manufacturers were offering small-scale
wood and charcoal fired "steam generation" power plants.
[0007] In Western countries, coal gasification systems began to
experience expanded interest during the 1980's as an alternative
for the utilization of natural gas and oil as the base energy
resource. Technology development perhaps mainly evolved as
fluidized bed gasification systems for coal, but also for the
gasification of biomass. Over the last 15 years, there may have
been much development of gasification systems as directed toward
the production of electricity and generation of heat in advanced
gas turbine based co-generation units.
[0008] Gasification of biomass perhaps can appear deceptively
simple in principle and many types of gasifiers have been
developed. The production of combustible syn-gas from biomass input
fuel may have attractive potential benefits perhaps such as ridding
the environment of noxious waste disposal problems, possible ease
of handling, and perhaps providing alternative energy production
with possibly the release of low levels of atmospheric
environmental contaminants. Further, cheap electricity generation
and the application of the produced syn-gas as an economical energy
source for the manufacture of liquid fuels may also often make
gasification very appealing.
[0009] However, the biomass input feedstock which is used in
gasifiers may challenge perceptions of uncomplicated design
simplicity since the feedstock material may represent varying
chemical characteristic and physical properties, perhaps as
inherent and unique to each individual biomass feedstock material.
The chemical reactions involved in gasification, relative to
processing the different varieties of available biomass materials,
may involve many different reactants and many possible reaction
pathways. The reaction rates are often relatively high; all these
variable factors may contribute to the perhaps very complex and
complicating nature of gasification processes. All too often
uncontrollable variables may exist that may make gasifiers hard to
mass balance control and perhaps to operate satisfactorily within
known preventive maintenance procedures, steady-state output
constants, and manageable environmental control compliance
areas.
[0010] Numerous U.S. patents have been issued relating to
alternative or renewable energy technology descriptions involving
gasification or syn-gas technologies. The present inventive
technology perhaps may overcome many of the operational
disadvantages associated with and perhaps commonplace to current
and commercially viable processes involving existing gasification
systems. The various types of available market updraft, downdraft,
air-blown, fixed bed, fluidized bed, circulating fluidized bed,
pulsed-bed, encapsulated entrained flow, and other gasification
systems may often have one or more serious disadvantages that
perhaps may be overcome by the present inventive technology.
[0011] In conventional gasification systems, disadvantages often
may exist that may create problems in perhaps a variety of areas,
including but not limited to areas such as: process control
stability related to input feedstock changes, steady state loading,
blockage and overall system throughput limitations; slagging
potential and challenges; scale-up sizing challenges; moisture
limitations; system gas and internal vapor leak challenges;
carry-through impurities and contamination challenges, system
plugging challenges (such as with excess char, tars or phenols);
problems with generated hydrocarbon volatiles and other corrosive
sulfur vapor carry-through contaminants being released into
produced synthesis gas; decreased BTU energy values in final
produced synthesis gas (such as due to excess CO.sub.2, N.sub.2, or
particulate contamination); and the like.
[0012] For example, conventional gasification systems may use
horizontal-plane screw for moving feedstock material, at controlled
throughput feed rates, into other competitive gasification thermal
reactor systems and also for simultaneously utilizing the enclosed
auger pipe housing (often using more than one auger system in a
one-to-the-other configuration) as an enclosed temperature stage
initial devolatilization zone. However, these combined double-duty
auger system designs may often be plagued with numerous and
sporadic mechanical, unpredictable and uncontrollable process
(negative) variables. Such variables can be considered as centering
around problems associated with input feed solids that can often
rope/lock disproportionally together or that can otherwise cause
plugging or binding of the auger shaft, helical flights and/or
blind the auger close tolerance receiver pipe cylinder openings.
This can in-turn warp the auger drive shaft into a bent and/or an
elliptical configuration. Auger shaft warpage can cause a high side
rotational internal friction wear and can rapidly create stress
cracks in an auger-pipe cylinder housing unit. This can cause
constant process pressure variation and can cause vapor leaks.
Excess friction drag can also break shafts. Further, intermittent
carbonaceous material bulk jams can occur whereby the throughput
devolatilization reactivity can be either lost or slowed. Feedstock
decomposition and devolatilization reactions can also begin to
occur at the surface of the plug/jam, therefore releasing, and
perhaps slowly devolatilizing, char solids, phenols, tars,
surfactants and other surface chemical hydrocarbon constituents
that can further liquefy and wax or seal the outer bulk-mass
surface of the plug materials into an even tighter and more
cementaceous plug. Incoming feedstock "plug mass" can quickly fill
into and blind the relatively small cross-section diameter surface
area narrower openings within typical auger screw pipe cylinder
housings. This can also begin to close off the auger screw conduit
that also serves as an initial devolatilization chamber.
[0013] The foregoing problems regarding conventional technologies
may represent a long-felt need for an effective solution to the
same. While implementing elements may have been available, actual
attempts to meet this need to the degree now accomplished may have
been lacking to some degree. This may have been due to a failure of
those having ordinary skill in the art to fully appreciate or
understand the nature of the problems and challenges involved. As a
result of this lack of understanding, attempts to meet these
long-felt needs may have failed to effectively solve one or more of
the problems or challenges here identified. These attempts may even
have led away from the technical directions taken by the present
inventive technology and may even result in the achievements of the
present inventive technology being considered to some degree an
unexpected result of the approach taken by some in the field.
SUMMARY DISCLOSURE OF INVENTION
[0014] The inventive technology relates to methods and apparatus
for solid carbonaceous materials synthesis gas generation and
embodiments may include the following features: techniques for
affirmatively establishing a stoichiometric objectivistic chemic
environment in a solid carbonaceous materials gasifier system;
techniques for stoichiometrically controlling carbon content in a
solid carbonaceous materials gasifier system; techniques for
multiple coil carbonaceous reformation in a solid carbonaceous
materials gasifier system; techniques for utilizing negatively
electrostatically enhanced water species in a solid carbonaceous
materials gasifier system; techniques for recycling materials
within a solid carbonaceous materials gasifier system; techniques
for dominative pyrolytic decomposition of carbonaceous materials
within a solid carbonaceous materials gasifier system; techniques
for solubilizing contaminants in a solid carbonaceous materials
gasifier system; techniques for recycling solubilized contaminants
within a solid carbonaceous materials gasifier system; techniques
for creating a high energy content select product gas from a solid
carbonaceous materials gasifier system; techniques for dynamically
adjusting process determinative parameters within a solid
carbonaceous materials gasifier system; techniques for
predetermining a desired select product gas for output from a solid
carbonaceous materials gasifier system; techniques for high yield
output of a select product gas from a solid carbonaceous materials
gasifier system; techniques for magnetic isolation of feedstock
solids carbonaceous materials constituent components in a solid
carbonaceous materials gasifier system; techniques for displacing
oxygen from feedstock solids carbonaceous materials in a solid
carbonaceous materials gasifier system; techniques for adjusting
process flow rates within a solid carbonaceous materials gasifier
system; and techniques for flue gas and/or product gas generation
and recycling within a solid carbonaceous materials gasifier
system. Accordingly, the objects of the methods and apparatus for
solid carbonaceous materials synthesis gas generation described
herein address each of the foregoing in a practical manner.
Naturally, further objects of the inventive technology will become
apparent from the description and drawings below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a conceptual view of a gasifier process flow path
with delimited functional areas in one embodiment.
[0016] FIG. 2 is a conceptual view of a gasifier process flow path
without delimited functional areas in one embodiment.
[0017] FIG. 3 is a front perspective view of a solid carbonaceous
materials gasifier system in one embodiment.
[0018] FIG. 4 is rear perspective view of a solid carbonaceous
materials gasifier system in one embodiment.
[0019] FIG. 5 is a sectional cutaway view of a multiple coil
carbonaceous reformation vessel in one embodiment.
[0020] FIG. 6 is a perspective view of a multiple coil carbonaceous
reformation vessel in one embodiment.
[0021] FIG. 7 is a perspective view of a multiple coil carbonaceous
reformation vessel in one embodiment.
[0022] FIG. 8 is a side cutaway view of a venturi injector in one
embodiment.
[0023] FIG. 9 is a cross section view of a venturi injector in one
embodiment.
[0024] FIG. 10 is a diagrammatic view of a negatively
electrostatically enhanced water species generation unit in one
embodiment.
[0025] FIG. 11 is a diagrammatic view of a select product gas
components scrubber in one embodiment.
[0026] FIG. 12 is a conceptual view of a pretreatment area of a
solid carbonaceous materials gasifier system in one embodiment.
[0027] FIG. 13 is a conceptual view of a pyrolytic decomposition
area of a solid carbonaceous materials gasifier system in one
embodiment.
[0028] FIG. 14 is a conceptual view of a carbonaceous materials
reformation area of a solid carbonaceous materials gasifier system
in one embodiment.
[0029] FIG. 15 is a conceptual view of an ash removal area of a
solid carbonaceous materials gasifier system in one embodiment.
[0030] FIG. 16 is a conceptual view of a scrubber area of a solid
carbonaceous materials gasifier system in one embodiment.
[0031] FIG. 17 is a conceptual view of an auxiliary-treatment area
of a solid carbonaceous materials gasifier system in one
embodiment.
[0032] FIG. 18 is a cross section view of a "pod" embodiment of the
present inventive technology.
[0033] FIG. 19 is a perspective view of a trailerable embodiment of
the present inventive technology.
[0034] FIG. 20 is a perspective view of a portion of a "pod"
embodiment of the present inventive technology.
[0035] FIG. 21 is a cross-section view of a reactor portion of a
"pod" embodiment of the present inventive technology.
[0036] FIG. 22 is a perspective view of a lower portion of a "pod"
embodiment of the present inventive technology.
MODES FOR CARRYING OUT THE INVENTION
[0037] The present inventive technology includes a variety of
aspects, which may be combined in different ways. The following
descriptions are provided to list elements and describe some of the
embodiments of the present inventive technology. These elements are
listed with initial embodiments, however it should be understood
that they may be combined in any manner and in any number to create
additional embodiments. The variously described examples and
preferred embodiments should not be construed to limit the present
inventive technology to only the explicitly described systems,
techniques, and applications. Further, this description should be
understood to support and encompass descriptions and claims of all
the various embodiments, systems, techniques, methods, devices, and
applications with any number of the disclosed elements, with each
element alone, and also with any and all various permutations and
combinations of all elements in this or any subsequent application.
As International Patent Application No. PCT/US2007/066466 in
incorporated herein in its entirety, including all claims filed
therein, such claims form part of this disclosure. In particular,
such claims describe a variety of features, steps, conditions, etc.
that may be combined in any arrangement with the claims that appear
explicitly at the end of this specification.
[0038] A solid carbonaceous materials gasifier system in various
embodiments perhaps may be configured to modular sections.
Embodiments may involve a system having functional areas (FIGS. 1;
4) perhaps such as: [0039] a pretreatment area (74), perhaps to
include bulk handling of input feedstock solid carbonaceous
material, displacement at least some oxygen content from the
feedstock solid carbonaceous material, and perhaps other
preparation handling for subsequent processing of the feedstock
solid carbonaceous material; [0040] a pyrolytic decomposition area
(75), perhaps to include varying a retention time of feedstock
solid carbonaceous material in a temperature varied environment, as
in perhaps a pyrolysis chamber; [0041] a carbonaceous materials
reformation area (77), perhaps to include carbonaceous reformation
of pyrolytically decomposed carbonaceous materials, such as in a
multiple coil reformation vessel or perhaps even in a helically
nested configuration of reformation coils in a multiple coil
reformation vessel; [0042] an ash removal area (78), perhaps to
include ash removal such as by downdraft cool-down and
pulse-evacuation containment; [0043] a scrubber area (79), perhaps
to include removal of contaminants from a generated select product
gas, such as by combined chill and spray of a negative
electrostatically enhanced water species and even polarized media
polish filtration; [0044] an auxiliary treatment area (76), perhaps
to include select product gas preparation for gasifier embodiment
combustion heating, such as with oxygen enrichment and reduction of
nitrogen content, perhaps utilizing an air separation unit.
[0045] Of course, these areas merely exemplify one possible modular
configuration for a solid carbonaceous materials gasifier system to
illustrate the concept of modularity in perhaps one embodiment, and
should not be regarded as limiting the possible modular
configurations of such a gasifier system, the distribution of
various gasification functions within modular sections of a
gasifier system, or indeed even to limit the inventive technology
to modular embodiments, consistent with the inventive principles
discussed herein.
[0046] The inventive technology may involve processes for carbon
conversion that perhaps may be categorized as gasification. Carbon
conversion may involve the conversion of carbon content in a
feedstock solids carbonaceous material, perhaps including a
majority or possibly even substantially all of such carbon content,
into select product gas components or even a select product gas. In
embodiments, such processes may include thermal processes, perhaps
including elevated temperatures in reducing conditions or with
little or no free oxygen present, to produce a select product gas,
such as a permanent and combustible synthesis gas. Such a select
product gas often may include predominantly CO and H.sub.2, with
some CH.sub.4 volume output, though the process control parameters
may allow significant control over the make-up of a produced select
product gas in particular applications. The process also may
involve minor by-products of various types, perhaps such as char
ash, condensable inorganics and organics, or trace
hydrocarbons.
[0047] In some embodiments, a solid carbonaceous materials gasifier
system may be initially started with an auxiliary fuel, such as an
external source of propane, as may be supplied to a gasifier system
process enclosure, for example such as to a box furnace enclosure
(26) (FIGS. 1; 2; 13) at a combustive burner (14) (FIGS. 1; 2).
This may be used, for example, perhaps until the reformation coils
(19) (FIGS. 1; 2; 3; 4) of a multiple coil reformation vessel reach
a suitable operational temperature, for example perhaps about
1600.degree. F. to 1800.degree. F. In some embodiments, this may
take approximately 24 hours. At this point some embodiments may be
capable of producing a select product gas whereby a fractional
portion may be returned to the combustive burner to sustain
combustion and maintain a desired process operational temperature.
In this manner, the system perhaps may become self-sustaining and
auxiliary fuel support may be shut off, perhaps with input delivery
of feedstock solids carbonaceous materials for processing to be
started or continued into the gasifier system.
[0048] A solid carbonaceous materials gasifier system in various
embodiments may include a gasifier process flow path originating at
a feedstock solids carbonaceous materials input and routed through
the solid carbonaceous materials process gasifier system. A process
flow path may provide a path by which solid carbonaceous materials
input into the gasifier system may be routed to various processing
areas of the gasifier system, perhaps ultimately for output of a
select product gas at a terminus of the gasifier process flow path.
Moreover, such a gasifier system perhaps may be characterized as
capable of receiving solid carbonaceous materials at the input of
the gasifier process flow path, which carbonaceous materials may be
solid in nature, perhaps as distinguished from fluidized bed and
updraft or downdraft gasifiers which often utilize liquid
feedstocks, slurried feedstocks, or other feedstock having
substantially non-solidified compositions. For example, such solid
carbonaceous material in some embodiments may include solid
carbonaceous particles milled to a size appropriate for throughput
through the gasifier system's process flow path, such as perhaps to
less than about 2 cubic inches in particle size. Moreover, the
dynamic adjustability of various process control parameters may
permit the gasifier system to accept a great variety of solid
carbonaceous materials for input, with the dynamic adjustability of
the gasifier system compensating for variations in the input
make-up to permit consistent output of desired select product gas.
For example, solid carbonaceous materials suitable for input may
include, but of course are not limited to, varied carbon content,
varied oxygen content, varied hydrogen content, varied water
content, varied particle sizes, varied hardness, varied density,
and the like, perhaps such as including varied wood waste content,
varied municipal solid waste content, varied garbage content,
varied sewage solids content, varied manure content, varied biomass
content, varied rubber content, varied coal content, varied
petroleum coke content, varied food waste content, varied
agricultural waste content, and the like.
[0049] A solid carbonaceous materials gasifier system in various
embodiments may be configured to process feedstock solids
carbonaceous materials in a variety of manners. Processing may
involve perhaps simply treating a carbonaceous material in some
capacity. For example, processing in various embodiments may
include pretreating a feedstock solids carbonaceous material within
a pretreatment area, pyrolytically decomposing in a pyrolysis
chamber, carbonaceously reforming in a multiple coil carbonaceous
reformation vessel, preliminarily carbonaceously reforming in a
preliminary carbonaceous reformation coil, secondarily
carbonaceously reforming in a secondary carbonaceous reformation
coil, tertiarily carbonaceously reforming in a tertiary
carbonaceous reformation coil, vaporizing a carbonaceous material
including perhaps vaporizing hydrocarbons or perhaps vaporizing
select product gas components, processing with a negatively
electrostatically enhanced water species, processing with
negatively electrostatically enhanced steam, processing with a flue
gas, processing with a pressurized flue gas, processing with a
preheated flue gas, processing with a scrubber recycled tar,
processing with a scrubber recycled phenol, processing with a
scrubber recycled solid, processing with a select product gas,
processing with a wet select product gas, processing with a dry
select product gas, processing with a recycled select product gas,
or other appropriate steps of treating carbonaceous materials
appropriate for gasification processes. Moreover, embodiments may
include multiple processing steps, which may be related as steps of
initial processing, subsequent processing, and the like. Of course,
such steps of processing may be accomplished by an appropriate
processor, for example a pretreatment area processor, a pyrolysis
chamber, a multiple coil carbonaceous reformation vessel, a
preliminary carbonaceous reformation coil of a multiple coil
carbonaceous reformation vessel, a secondary carbonaceous
reformation coil of a multiple coil carbonaceous reformation
vessel, a tertiary carbonaceous reformation coil of a multiple coil
carbonaceous reformation vessel, and the like.
[0050] A feedstock solids carbonaceous materials input in some
embodiments may include a walking floor or other raw feedstock
holding bin (1) (FIGS. 1; 2; 12), perhaps with a continuous volume
of input feedstock solids carbonaceous material that has been
previously milled or shredded to an input particle size not to
exceed as desired. Further, in embodiments, an inventory storage
volume may be selected, for example perhaps a five day inventory
storage volume, to ensure a consistent supply of feedstock
carbonaceous materials for input. In embodiments, gasifier system
exhaust flue gas (9) (FIGS. 1; 2; 12), produced for example perhaps
by combustive burners, may be directed to a compressor, such as a
high temperature delivery compressor (8) (FIGS. 1; 2; 12), whereby
the flue gas temperature may be reduced from a high temperature,
perhaps approximately 700.degree. F., to a lower temperature. This
may occur via an in-line heat exchanger or the like, not shown. In
embodiments, temperature reduction may be down to about 300.degree.
F. Further, the compressor may also pressure regulate small volume
and may also intermittently inject hot flue gas into a holding bin
to additionally dry out moisture within the feedstock solids
carbonaceous material, if required. A suitable feedstock delivery
system, such as a variable speed horizontal metering screw (not
shown), may be used to deliver a controlled rate volume feed of
feedstock solids carbonaceous material to a variable speed inclined
conveyor (2) (FIGS. 1; 2; 3; 4; 12) or the like.
[0051] A pressure system in some embodiments may be joined to a
gasifier process flow path to pressurize the feedstock solids
carbonaceous material as appropriate, for example perhaps by
configuring the variable speed inclined conveyor to be sealed,
perhaps such as in a pressure-tight unit cylinder. Such a pressure
system also may include a flue gas delivery compressor to perhaps
also pressure regulate a small but continuous volume delivery of
hot flue gas into a conveyor unit, perhaps sealed cylinder, with
perhaps an about 40 psi pressure being maintained throughout the
conveyor feed cylinder. This may be fed into an inlet feed plenum
assembly (6) (FIGS. 1; 2; 3; 12). The pressure system further may
involve a conveyor unit cylinder pressure (perhaps flanged) sealed
to an inlet plenum assembly, and the conveyor drive motor perhaps
may be mounted outside the conveyor pressure unit cylinder.
Further, a motor drive shaft may also be pressure sealed as part of
a pressure system perhaps through the wall of a conveyor housing
cylinder. Flue gas may be further compressed and pressure regulated
and injected at the top of an inlet, perhaps airtight, plenum. This
may occur such as at injection position (3) (FIGS. 1; 2; 12).
Location and amount may be selected to ensure that a desired
continuous pre-heat temperature, such as approximately 300.degree.
F. and 40 psi positive pressure, is maintained in the inlet plenum
chamber.
[0052] In addition to the benefit of hot flue gas drying out excess
feedstock moisture, hot flue gas may be used to displace and starve
excess air out of the input feedstock materials. Such use of hot
flue gas may be employed as part of an oxygen displacement system,
which may represent a meaningful process control variable to limit
air content, including perhaps oxygen levels, in the inlet plenum
feed assembly. Such an oxygen displacement system may be employed
gravimetrically, for example perhaps by injecting flue gas at the
bottom of an incline, perhaps via an incline base input, through
which a feedstock solids carbonaceous material may be moved and
releasing oxygen content from the top of the incline, for example
perhaps via an incline apex output. In some process configurations
hot product gas may be substitute added, instead of utilizing flue
gas, to achieve the same drying and displacement benefits and add
more carbon element return. In some embodiments, such an incline
may be a variable speed inclined conveyor (2) (FIGS. 1; 2; 3; 4;
12) or the like. Gravimetric displacement may occur as the injected
flue gas rises gravimetrically through the incline, perhaps
physically displacing air content and oxygen content along the way.
Release of the displaced air or oxygen content may be affected
through use of a suitable port, valve, outlet, or the like, at the
top of the incline. Moreover, while injected flue gas may suffice
for oxygen displacement, it may be appreciated that any suitable
substance may be injected consistent with the gravimetric
principles herein described, including for example using flue gas,
using pressurized flue gas, using preheated flue gas, using
recycled flue gas, using select product gas, using wet select
product gas, using dry select product gas, using recycled select
product gas, and the like. Of course, temperature and pressure
characteristics of these injected substances may be selected as
appropriate to achieve oxygen displacement, including for example
pressurizing to at least 40 psi and preheating to at least 300
degrees Fahrenheit.
[0053] Further, the flue gas may consist of large concentrations of
CO which may assist in the conversion of volatile gases to release
free carbon. Periodic small volumes of plenum flue gas may also be
auto-vented as a safety relief perhaps such as through an exhaust
filter (5) (FIGS. 1; 2; 12) and a pressure relief/control valve
(71) (FIGS. 1; 2; 13) which may be configured at the top of a
plenum exhaust bleed outlet (4) (FIGS. 1; 2; 12). This may also be
directed to an external flare system.
[0054] A gasifier flow path may be routed through one or more
suitable airlock components to maintain pressure in a pressure
system, for example a rotary type airlock material feed-through
valve (not shown). Such airlock components may be configured to
ensure that a desired pressure, for example perhaps a constant 40
psi pressure, can be held among the pressurized components of the
system, for example perhaps at the plenum delivery system. Such
maintained pressure also may prevent the back-feed of materials
from subsequent processing areas of the gasifier system. In
addition, by maintaining a perhaps 40 psi or so positive plenum
pressure, the downward injection of feedstock solids carbonaceous
materials into subsequent processing areas may be pressure
assisted. In embodiments, the feedstock solids carbonaceous
materials may transfer by gravity through a suitable airlock
component, for example perhaps through wide throat airlock valves.
In this arrangement, one valve may sequence into an open position
while the other valve remains in a closed position, thereby
allowing a volume of feedstock material to be retained in a holding
chamber between the two valves. In this, or other manners, when the
lower valve opens, the feedstock material may drop into a
connecting conduit, perhaps through a box furnace enclosure (26)
(FIGS. 1; 2) and into a subsequent processing areas of the gasifier
system (FIGS. 1; 2).
[0055] Of course, a pressure system through which a gasifier
process flow path is routed should not be construed as limited
merely to the foregoing examples described herein. Rather, a
pressure system perhaps simply may involve maintaining one or more
areas within a solid carbonaceous materials gasifier system at a
different pressure than that outside of the solid carbonaceous
materials gasifier system. Such pressure maintenance may be
accomplished in any suitable manner consistent with the principles
described herein, for example perhaps through the use of an
airlock, a double airlock, an injector that injects a pressurized
substance such as a pressurized flue gas or pressurized select
product gas, or perhaps even an inductor configured to maintain a
pressure. Moreover, a pressure system may be applied to any
gasifier system enclosures for which pressurization may be
required, such as perhaps a pretreatment environment enclosure, a
pyrolysis chamber enclosure, a multiple coil carbonaceous
reformation vessel enclosure, any or all parts of a gasifier
process flow path routed through a solid carbonaceous materials
gasifier system, and the like. In some embodiments, a pressure
system may be sealed, for example as to prevent communication
between the pressurized environment and an unpressurized
environment or perhaps to seal a feedstock solids carbonaceous
material within the solid carbonaceous materials gasifier
system.
[0056] Various embodiments may involve joining a heater system to a
gasifier process flow path. Joining may be understood to involve
perhaps simply brining two elements into some degree of mutual
relation, for example, a heater system joined to a gasifier process
flow path simply may permit the heater system to heat at least some
of the gasifier process flow path. Heating in this manner may be
effected in any suitable manner, for example perhaps by a
combustive burner, an electric heater or the like. In various
embodiments, a heater system may be configured to supply heat
appropriate for a particular processing stage. In this manner, a
heater system in various embodiments may include pyrolysis
temperature heater system, a carbonaceous reformation temperature
heater system, a variable temperature zone heater system, a heater
system configured to establish a temperature from 125.degree. F. to
135.degree. F., a heater system configured to establish a
temperature from 135.degree. F. to 300.degree. F., a heater system
configured to establish a temperature from 300.degree. F. to
1,000.degree. F., a heater system configured to establish a
temperature from 1,000.degree. F. to 1,640.degree. F., and a heater
system configured to establish a temperature from 1,640.degree. F.
to 1,850.degree. F.
[0057] In various embodiments, a gasifier process flow path may be
routed through a temperature varied environment. A temperature
varied environment may include a contiguous portion of a gasifier
process flow path heated to varied temperatures, as for example by
a variable temperature zone heater system. Some embodiments may use
a gravity drop flow of feedstock material such as from the bottom
of airlock valve (7) (FIGS. 1; 2; 3; 4; 12) and through the wall of
a box furnace enclosure (26) (FIGS. 1; 2; 13). This perhaps may be
arranged directly into a temperature varied environment, perhaps
where one or more dynamically adjustable process flow parameters
may be utilized to process the feedstock solids carbonaceous
material. Overall operational temperature such as within a
temperature varied environment may be regulated so that an inlet
conduit entering from a previous processing area may provide
incoming feedstock solids carbonaceous materials at an elevated
temperature, perhaps such as at approximately 250.degree. F. to
300.degree. F., and perhaps as dependant upon any of various
suitable dynamically adjustable process determinative parameters,
such as the volume of a negatively electrostatically enhanced water
species or the temperature of an injected flue gas. A temperature
gradient may be established within the temperature varied
environment perhaps from about 300.degree. F. at an input area and
reaching about 900.degree. F. to 1000.degree. F. toward an output
area. Of course, any suitable heater system capable of variable
heat output may be used to achieve such variable temperature zones.
In some embodiments, for example, a series of electric heaters,
combustive burners, or the like may be configured to produce a
temperature varied environment.
[0058] A temperature varied environment in various embodiments may
include a liquefaction zone. A liquefaction zone may be a
temperature zone of a varied temperature environment in which
feedstock solids carbonaceous materials may tend to liquefy, for
example such as by being heated to their liquefaction temperature.
Embodiments may include a plurality of movement guides in a
temperature varied environment, perhaps temperature variable
movement guides capable of being heated to varied temperatures as a
result of being moved through said temperature varied environment,
perhaps including trans-liquefaction movement guides disposed
through the temperature varied environment that may engage a
feedstock solids carbonaceous material for transport through the
temperature varied environment and liquefaction zone. Such movement
through the liquefaction zone may include receiving a feedstock
solids carbonaceous material at a pre-liquefaction temperature zone
of the temperature varied environment, which may perhaps be a
cooler temperature than required to liquefy the feedstock solids
carbonaceous material, moving the feedstock solids carbonaceous
material through the liquefaction zone, at which point the
feedstock solids carbonaceous material may liquefy, and moving the
liquefied feedstock solids carbonaceous material into a
post-liquefaction temperature zone, which may perhaps be a hotter
temperature than the liquefaction temperature of the feedstock
solids carbonaceous material.
[0059] In some embodiments, a plurality of trans-liquefaction
movement guides may be joined to a temperature varied cyclical
return. Such a temperature varied cyclical return may permit the
trans-liquefaction movement guides to move through the temperature
varied environment on a cyclical path. A trans-liquefaction
movement guide undergoing such cyclical motion, for example, may
begin within one temperature zone of the temperature varied
environment, move through one or more other temperature zones of
the temperature varied environment, and be returned to its original
starting position within the first temperature zone of the
temperature varied environment, where the cycle may be repeated. Of
course, any of a variety of appropriate devices may accomplish such
cycling. In some embodiments, for example, a temperature varied
cyclical return may include an endless loop conveyor system,
perhaps such as a track feeder (10) (FIGS. 1; 2; 3; 4; 13).
Embodiments also may include varying the speed at which a
temperature varied cyclical return is operated, perhaps to vary a
retention time at which feedstock solid carbonaceous materials
engaged by a plurality of trans-liquefaction movement guides may be
retained within a temperature varied environment. In this manner, a
track feeder (10) (FIGS. 1; 2; 3; 4; 13) may be provided with a
variable return cycle.
[0060] In some embodiments, movement guides may be translatable
movement guides. Configuring movement guides to be translatable may
involve moving a feedstock solids carbonaceous material engaged to
the movement guide by physically translating the movement guide
itself. For example, where movement guides in embodiments may be
joined to a temperature varied cyclical return, the cyclical motion
of the return may act to physically translate the position of the
movement guides, as perhaps through the cyclical motion of the
return. Moreover, such a translatable nature of movement guides may
be compared to non-translating motion systems, for example perhaps
rotating screw systems, wherein the position of the screw itself
may not translate and motion may be imparted simply by the rotation
of the screw. In some embodiments, the translatable nature of the
movement guides may assist in preventing binding of the movement
guides by liquefied feedstock solids carbonaceous materials,
perhaps in as much as translating the position of the movement
guides may serve to translationally push liquefying feedstock into
a higher temperature zone, and even possibly by cyclically varying
the temperature of the movement guides themselves to avoid holding
them at a liquefaction temperature.
[0061] Cycling movement guides in a temperature varied environment
further may include automatically periodically clearing the
movement guides of feedstock solids carbonaceous materials that may
have liquefied when moved through a liquefaction zone. For example,
cycling may involve continuously varying the temperature of the
movement guides, perhaps including cyclically raising and lowering
the temperature of the movement guides as they are cycled through a
varied temperature regime. Such temperature change of the movement
guides may be alternately through a pre-liquefaction temperature
and a post-liquefaction temperature, avoiding holding of the
movement guides at a liquefaction temperature, and in this manner
it may be seen that liquefied feedstock solids carbonaceous
material to which individual movement guides are engaged may be
vaporized as the movement guides cycle through their
post-liquefaction temperatures. Accordingly, the movement guides
may be automatically periodically cleared as a result of such
cycling, and binding of the movement guides may be avoided in as
much as the liquefied dry solids carbonaceous feedstock may be
systematically vaporized. In this manner, the movement guides may
be considered as configured to avoid a sustained liquefaction
temperature, configured for cyclical elevation and reduction in
temperature, configured for cyclical liquefaction and vaporization
of feedstock solids carbonaceous material, and may even be
considered to be binding resistant movement guides.
[0062] A track feeder and plurality of trans-liquefaction movement
guides in some embodiments may be configured to include a
track-heat-scraper plate. For example, in some embodiments, along
the bottom longitudinal centerline underside of a track
heat-scraper plate (not shown) may be located a parallel row of
progressive electric heaters (11) (FIGS. 1; 2; 13) that may even
sequentially control a temperature gradient. Similarly, in some
embodiments a select product gas burner manifold may be used as a
heating source and perhaps may be located external and adjacent to
the track feeder embodiment. A scraper wear plate may be
periodically replaced as required and may even be fabricated and
cast from hardened high temperature metallic material. A
counter-clockwise rotation of a feeder track may be used to move
feedstock solids carbonaceous material to the bottom underside of
the track feeder.
[0063] Moreover, in some embodiments, such varied temperatures may
include pyrolysis temperatures suitable to pyrolytically decompose
at least some of a feedstock solids carbonaceous material routed
through the temperature varied environment along a gasifier process
flow path. Pyrolysis may involve heating the feedstock solids
carbonaceous material in the absence of reactively significant
amounts of oxygen to induce decomposition of the feedstock solids
carbonaceous material, as perhaps by consequential thermal
reactions, chemical reactions, and volatilization reactions. The
absence of such reactively significant amounts of oxygen perhaps
need not require the total absence of oxygen (although this
condition certainly may be included), but rather perhaps may
include merely an amount of oxygen that produces merely
insubstantial or perhaps even nonexistent combustion when said
feedstock solids carbonaceous material is subjected to the
temperature varied environment. In various embodiments,
pyrolytically decomposing may involve vaporizing a carbonaceous
material, for example perhaps vaporizing hydrocarbons or perhaps
vaporizing select product gas components. Further, in some
embodiments, portions of a temperature varied environment in which
pyrolytic decomposition may occur accordingly may be considered to
include a pyrolysis chamber.
[0064] In some embodiments, pyrolytically decomposing a feedstock
solids carbonaceous material in a temperature varied environment
may include dominatively pyrolytically decomposing the feedstock
solids carbonaceous material. Such dominative pyrolysis may involve
pyrolyzing to a high degree, perhaps by subjecting the feedstock
solids carbonaceous material to prolonged pyrolyzing conditions.
For example, embodiments may include retaining a feedstock solids
carbonaceous material within a pyrolysis chamber of a temperature
varied environment for at least 2 minutes, at least 3 minutes, at
least 4 minutes, at least 5 minutes, at least 6 minutes, at least 7
minutes, at least 8 minutes, at least 9 minutes, at least 10
minutes, at least 11 minutes, at least 12 minutes, at least 13
minutes, at least 14 minutes, at least 15 minutes, at least 16
minutes, at least 17 minutes, at least 18 minutes, at least 19
minutes, or at least 20 minutes, for example perhaps by varying the
speed of a temperature varied cyclical return and a plurality of
movement guides joined to the temperature varied cyclical return.
Such retention times perhaps may be substantially longer than
conventional pyrolysis times, and perhaps may be achievable by
minimizing or perhaps even eliminating binding caused by
liquefaction that perhaps may plague conventional pyrolysis
systems.
[0065] Moreover, pyrolysis or even dominative pyrolysis may be
facilitated in various embodiments by maximizing the surface area
of a track feeder to increase the surface area contact of a
feedstock solids carbonaceous material to the pyrolysis conditions
of a pyrolysis chamber. For example, embodiments may include
maximizing the surface area of a track feeder (10) (FIGS. 1; 2; 3;
4; 13), for example including perhaps dimensioning the track feeder
to at least 24 inches in width, to at least 30 inches in width, to
at least 36 inches in width, to at least 42 inches in width, to at
least 48 inches in width, to at least 54 inches in width, to at
least 60 inches in width, to at least 66 inches in width, to at
least 72 inches in width, to at least 3 feet in length, to at least
6 feet in length, to at least 9 feet in length, to at least 12 feet
in length, to at least 15 feet in length, to at least 18 feet in
length, and to at least 21 feet in length. Such dimensions may be
perhaps at ten to twenty times greater surface area exposure than a
conventional 3 or 4 stage auger feed pyrolysis system design, and
may be without the binding or plugging probabilities mentioned
earlier.
[0066] A track feeder in various embodiments may represent an
integrated process control module, perhaps with sequenced computer
automation. Process flow embodiments may be monitored to provide an
adjustable time period to extend or shorten pyrolytic decomposition
times for throughput feedstock solids carbonaceous material to
undergo perhaps complete reaction contact with heat, flue gas CO,
negatively electrostatically enhanced water species, and the like.
A track feeder system design in various embodiments may be sized to
automatically process perhaps about 50 tons/day and up to 500
tons/day of input feedstock solids carbonaceous materials. Of
course, multiple track feeders, perhaps routed through multiple
temperature varied environments perhaps including pyrolysis
chambers, may be utilized in some embodiments to increase total
feedstock solids carbonaceous materials throughput. Track feeder
maximized surface areas, adjustable temperatures, progressive time
controls, and track speed control variables may be included in
embodiments such as to allow extended pyrolysis time or the like
and to provide a capability to near completely pyrolytically
decompose the feedstock solid carbonaceous material, including
perhaps tars and phenolic chemistry fractions. In some embodiments,
small volume additions of calcined dolomite also may be added, for
example at a pretreatment area, such to speed up and catalyze the
sulfurs or tars and phenols initial cracking process that may occur
in the pyrolysis chamber. Track feeder operational up-time may even
approach 100%, except perhaps for short 2-3 day periods of monthly
preventive maintenance. The components of a track feeder, such as
chains, sprockets, and drive shafts, perhaps may be manufactured
from high temperature Inconel.RTM. alloy metal stock or the like,
or other alternate and appropriate metallic materials, and in
addition, components such as track flights and bottom track scraper
wear and heater plates (not shown) may be custom cast with high
temperature metallurgy or the like. Track feeder drive bearings may
be standard nuclear industry high temperature sealed units, perhaps
with an outboard variable speed motor drive unit that may provide a
track rotational movement selection of one to five revolutions per
minute. An additional auto-vent safety-relief pressure control and
relief valve (71) (FIGS. 1; 2; 13; 14) may be installed and perhaps
even centered through the top of a box furnace enclosure (26)
(FIGS. 1; 2; 13). Of course, the use of a temperature varied
cyclical return as described herein may preclude the need for any
type of auger screw or perhaps even any screw type movement system
through a pyrolysis chamber of a temperature varied environment as
described herein.
[0067] Various embodiments further may include a magnetic materials
removal system (12) (FIGS. 1; 2) through which a gasifier process
flow path is routed, perhaps to magnetically isolate at least one
constituent component of a feedstock solids carbonaceous material.
Such a magnetic materials removal system may use a magnet to
magnetically attract metallic constituent components of a feedstock
solids carbonaceous material. Where a nonmetallic constituent
component is desired to be removed, embodiments perhaps may still
achieve removal of such nonmetallic constituent components perhaps
by creating a metal oxide of the nonmetallic constituent
components, perhaps in a metals oxidation area, and magnetically
attracting the created metal oxide. In some embodiments, oxidation
may be achieved by reacting such constituent components with a
negatively electrostatically enhanced water species, perhaps as
injected into a gasifier process materials flow path, and
magnetically attracting the reacted constituent component.
Moreover, such magnetically isolated constituent components may be
removed from a gasifier process flow path, for example perhaps by
being gravimetrically deflected away from a gasifier process flow
path and received into an electromagnetic drop well. Such
gravimetric deflection of course may be enhanced by a magnet. In
various embodiments, such an electromagnetic drop well may be
located to receive removed constituent components prior to exit
from a temperature varied environment, perhaps even after pyrolytic
decomposition of a feedstock solids carbonaceous material. Removal
of such magnetically isolated constituent components further may
reduce abrasion within the solid carbonaceous materials gasifier
system that otherwise may have been caused by the constituent
component. Such removal also may assist in increasing the purity of
a select product gas, increasing the BTU content of a select
product gas, minimizing contaminants within a select product gas,
or perhaps even creating a magnetic materials demagnetized select
product gas.
[0068] In some embodiments, pyrolytically decomposed carbonaceous
material, such as perhaps generated, devolatilized reactive vapor
and atomized particulate material, may pass into and through a
venturi injector (13) (FIGS. 1; 2; 4; 8; 14). This in turn may have
a pressure-tight fitting to the inlet of multiple coil carbonaceous
reformation vessel (19) (FIGS. 1; 2; 3; 4; 14). A venturi injector
(13) (FIGS. 1; 2; 4; 8; 14) may be connected directly to an input,
perhaps an inlet pipe opening, of the innermost reformation coil
(15) (FIGS. 1; 2; 5; 6; 7; 14), perhaps preliminary reformation
coil, of a multiple coil carbonaceous reformation vessel. Venturi
side-entry inputs may provide the option of produced select product
gas, generated negatively electrostatically enhanced water species,
or perhaps both to be injected into the reformation coils, for
example perhaps at the initial entry opening of the first innermost
reformation coil (15) (FIGS. 1; 2; 5; 6; 7; 14). As an additional
process safeguard, a side-stream small volume of select product gas
may be made available for return injection such as into the
multiple coil carbonaceous reformation vessel (19) (FIGS. 1; 2; 3;
4; 14), perhaps even such as into and through the venturi injector
(13) or through venturi injector (17) (FIGS. 1; 2; 8; 9; 14). This
may provide for additional select product gas motive velocity and
pressure perhaps to move carbonaceous materials entrained in a
gasifier process flow continuously into and through all reformation
coils (15), (16) and (18) (FIGS. 1; 2; 5; 6; 7; 14) of a multiple
coil carbonaceous reformation vessel 19. In the event of a
momentary mechanical or process depletion availability of
accessible flue gas, select product gas, or perhaps both, a rapid
shutdown purge may be made available for providing a complete
multiple coil carbonaceous reformation vessel vent-cleaning,
perhaps by back-feeding system process water into the multiple coil
carbonaceous reformation vessel (19) (FIGS. 1; 2; 3; 4; 14). Coil
latent heat may provide thermal energy to produce an immediate
steam cleaning action, if and when required due to an emergency
shutdown circumstance. The availability of providing negatively
electrostatically enhanced mist injection directly into the initial
reformation coil, at the point of venturi injection (13) (FIGS. 1;
2; 4; 8; 14), and/or venturi injector (17) (FIGS. 1; 2; 8; 9; 14),
may further provide near instantaneous and immediate steam
reformation reaction-control. If either high surfactant or tarry or
waxy chemistry exists, or if very dry input feedstock solids
carbonaceous material is to be processed, or even if additional,
perhaps merely more flexible, process control variables may be
desired, an element such as a venturi injector (17) (FIGS. 1; 2; 8;
9; 14) may be applied with an alternate embodiment for venturi
injector (13) also shown.
[0069] In some embodiments, a negatively electrostatically enhanced
water species, possibly including negatively electrostatically
enhanced steam, may be added to a temperature varied environment.
Such addition of a negatively electrostatically enhanced water
species may represent a dynamically adjustable process
determinative parameter implemented in the temperature varied
environment. The negatively electrostatically enhanced water
species perhaps may be routed through a return injection line (51)
(FIGS. 1; 2), and perhaps may be preheated to an elevated
temperature, such as perhaps about 1,800.degree. F., and may
possibly be preheated via routing through a box furnace enclosure
(26) (FIGS. 1; 2; 13; 14). Adding the negatively electrostatically
enhanced water species may involve mist spraying, perhaps using a
venturi (not shown), upon incoming feedstock solid carbonaceous
material that may be engaged by a track feeder (10) (FIGS. 1; 2; 3;
4; 13). External valve control may be included to allow the
addition of the negatively electrostatically enhanced water species
to be metered for determining an optimum process control
set-point.
[0070] Embodiments may further involve adding a flue gas to the
temperature varied environment, perhaps such a pressurized flue
gas, a flue gas pressurized to at least 80 psi, or a flue gas in
motion at a rate of about 75-100 cfm. Such addition of a flue gas
may represent a dynamically adjustable process determinative
parameter. For example, such addition of a flue gas may be used to
further affect temperature of a feedstock solids carbonaceous
material, and may provide motive force pressurization within the
temperature varied environment. For example, perhaps simultaneous
to the point of negatively electrostatically enhanced water species
injection into the temperature varied environment, additional hot
flue gas may be compressed and pressure regulated, perhaps to at
least about 80 psi, from an exhaust flue gas compressor (8) (FIGS.
1; 2; 12). This may be coactively venturi-injected (not shown) such
as to perhaps join a spray of the negatively electrostatically
enhanced water species mixing with incoming feedstock solids
carbonaceous material. This may not only establish further process
determinative parameters that may allow the negatively
electrostatically enhanced water species to react and assist in
accelerating more complete pyrolytic decomposition, but may also
provide for the injection of additional reactive flue gas carbon
monoxide content, perhaps to accelerate vapor pressure reactions.
The injection of pressurized flue gas also may assist in regulating
and perhaps maintaining pressure within the temperature varied
environment, for example perhaps 80 psi or higher control pressure
if desired. Also, heat from an added preheated flue gas may be
employed to contribute to the overall heat balance, perhaps
reducing heat requirements from other gasifier system elements.
[0071] Moreover, embodiments further may provide for adding select
product gas to achieve the same process control benefits as adding
flue gas, adding wet select product gas, adding dry select product
gas, adding recycled select product gas, adding a scrubber recycled
tar, adding a scrubber recycled phenol, adding scrubber recycled
carbon dioxide, and adding a scrubber recycled solid to a
temperature varied environment. Such additions of course also may
represent dynamically adjustable process determinative
parameters.
[0072] Accordingly, in various embodiments, a temperature varied
environment may incorporate one or more dynamically adjustable
process determinative parameters, perhaps utilized singly or in
combination. Initial feedstock solids carbonaceous materials
decomposition, perhaps pyrolytic decomposition, may occur perhaps
across a moving track feeder bottom-side length of progressive
temperature increase through a temperature gradient. In
embodiments, this may range from approximately 300.degree. F. to
900.degree. F., and may even occur as movement guides, perhaps
track flights, scrape forward carbonaceous material, as perhaps
along a surface of a track feed heater contact plate (not shown).
Feedstock solids carbonaceous material may move forward and may
gradually both dissociate and volatilize into smaller solids and
particulates, and initial carbon conversion gases may be released.
Further, the feedstock solids carbonaceous material may partially
liquefy, perhaps along with organic content beginning to volatilize
into hydrogen gas, carbon monoxide gas, hydrocarbon vapors, and
perhaps other select product gas components. By controlling and
adjusting the retention time, perhaps through track feeder speed
variation, the feedstock solids carbonaceous material may be
subjected to and may pass through the majority of any or all char
decomposition reactions, and perhaps liquefaction stages. There may
even be a near 100% throughput delivery of decomposed, perhaps
pyrolytically decomposed, carbon-bearing fine particulate material
and initial devolatilized gas cross-over into a subsequent gasifier
system processing stage, such as perhaps a multiple coil
carbonaceous reformation vessel. Any residual amount of remaining
larger-particle char, solids, or inorganic metallic or inert
material, including perhaps para-magnetic organic or metal
compounds, may become attracted and isolated into a electromagnetic
drop well (12) (FIGS. 1; 2; 13). These isolated, perhaps smaller
volume materials may be intermittently transferred through an
airlock receiver (not shown) to an external container. Any
incompletely decomposed carbonaceous material of larger particle
size perhaps may be screen classified and separated away from other
drop-well silica or magnetic debris and recycle returned, such as
back to a walking floor feed hopper.
[0073] Not only may the physical kinetics of changing track feeder
speed allow the decomposition completion time to become optimized
for various chemistries of different feedstock solids carbonaceous
materials, but other synergistic dynamically adjustable process
determinative parameters may be applied, either individually or
collectively, perhaps to optimize near total decomposition, and
perhaps to maximize initial devolatilization gaseous transfer such
as to subsequent gasifier system processors. Dynamically adjustable
process determinative parameters may exist, perhaps such as: heat
and temperature variations which may be altered or increased; flue
gas injected concentrations, perhaps carbon monoxide ratios, may be
adjusted; negatively electrostatically enhanced water species
dilution and injection ratios may be modified to accelerate carbon
shift and steam reformation; throughput select product gas
components pressure reaction velocities may be altered; and
resultant carry-through vapor and fine, perhaps carbon-bearing,
particulate or ash mass balance ratios may be modified and adjusted
to achieve optimum select product gas production volumes.
[0074] A solid carbonaceous materials gasifier system in various
embodiments may be configured to recycle various substances routed
through a gasifier process flow path. Such recycling may involve
returning materials put through or perhaps generated at a later
processing stage within the carbonaceous materials gasifier system
to an earlier processing stage of the carbonaceous materials
gasifier system. In various embodiments, such return may be via a
recycle path appended to the later processing stage and routed to a
recycle input joined to the gasifier process flow path at an
earlier processing stage. Moreover, recycling in various
embodiments may involve significantly internally recycling, for
example where a substantial majority of the recycle material may be
retained within the solid carbonaceous materials gasifier system,
including perhaps all or nearly all of such a recycle material.
Recycling in various embodiments perhaps even may include exceeding
an environmental standard for recycling such materials.
[0075] For example, a generalized process flow for a solid
carbonaceous materials gasifier system in some embodiments may
involve initially processing at least a portion of a feedstock
solids carbonaceous material, creating an initially processed
carbonaceous material, subsequently processing the initially
processed carbonaceous material, perhaps to generate at least some
components of a select product gas, and creating a subsequently
processed carbonaceous material. The subsequently processed
carbonaceous material perhaps may be selectively separated, as into
a first processed material portion and a second processed materials
portion. The first processed materials portion then perhaps may be
returned, for example perhaps utilizing an appended recycle path to
a recycle input of the gasifier process flow path. Some embodiments
perhaps may involve mixing the returned first processed materials
portion with an additionally input carbonaceous material, for
example perhaps with a feedstock solids carbonaceous materials
re-mixer, and reprocessing.
[0076] Of course, the steps of initially processing, subsequently
processing, and reprocessing may involve any appropriate kind of
processing of carbonaceous material consistent with the
gasification principles discussed herein--all that may be required
is that the step of initially processing occur before the step of
subsequently processing, and that the step of subsequently
processing occur before the step of reprocessing. For example,
these steps of processing may include pretreating a carbonaceous
material, pyrolytically decomposing a carbonaceous material,
carbonaceously reforming a carbonaceous material in a multiple coil
carbonaceous reformation vessel, preliminarily carbonaceously
reforming a carbonaceous material in a preliminary reformation
coil, secondarily carbonaceously reforming a carbonaceous material
in a secondary reformation coil, and tertiarily reforming a
carbonaceous material in a tertiary reformation coil. In addition,
returning in various embodiments may be implemented perhaps by a
venturi, or perhaps even a venturi injector, for example perhaps to
maintain pressure conditions or flow rate conditions through a
recycle path, for example such as a pressure from about 50 psi to
about 100 psi or a flow rate from about 2,000 fpm to about 8,000
fpm.
[0077] Moreover, recycling in various embodiments may involve
selecting a recycle path, perhaps as from a multiply routable path.
Such a multiply routable path may provide two or more recycle path
options through which recycled materials may be returned. For
example, with reference to the generalized process flow described
herein, one example of a multiply routable path may involve
initially processing in a pyrolysis chamber, subsequently
processing in a preliminary reformation coil, returning a first
processed materials portion to the pyrolysis chamber, and
reprocessing in the pyrolysis chamber. Another example may involve
initially processing in a preliminary reformation coil,
subsequently processing in a secondary reformation coil, returning
the first processed materials portion to the preliminary
reformation coil, and reprocessing in the preliminary reformation
coil. Of course, these are merely examples illustrative of some
possible configurations for a multiply routable path in some
embodiments, and should not be construed to limit the possible
configurations for a multiply routable path consistent with the
principles described herein.
[0078] In various embodiments, materials routed through a gasifier
process flow path may be selectively separated. Such selective
separation perhaps may involve selecting a property of the material
to be separated and effecting separation by utilizing that
property. Examples of such selective separation perhaps may include
screening, solubilization, magnetism, or the like. In some
embodiments, selective separation may be accomplished through the
vortex action of a cyclone. For example, embodiments may include
operating a cyclone at conditions including perhaps from 50 psi to
100 psi, 1,640.degree. F. to 1,800.degree. F., and 2,000 fpm to
8,000 fpm, and achieving the selective separation of gasifier
process flow path materials accordingly. Moreover, selectively
separating may include on the basis of particle size, for example
perhaps selectively separating carbonaceous particles of at least
350 micron particle size, selectively separating carbonaceous
particles of at least 150 micron particle size, selectively
separating carbonaceous particles of at least 130 micron particle
size, selectively separating carbonaceous particles of at least 80
micron particle size, selectively separating carbonaceous particles
of at least 50 micron particle size, selectively separating
carbonaceous particles of at least 11 micron particle size,
selectively separating carbonaceous particles of at least 3 micron
particle size, and selectively separating ash. Other modes of
selectively separating may include physically separating,
separating by phase, separating by density, separating by
screening, separating by incompletely pyrolytically decomposed
carbonaceous material, separating by incompletely carbonaceously
reformed material, separating by heterogeneous composition, and the
like. Moreover, selectively separating consistent with the
techniques described herein may remove certain impurities from a
gasifier process flow, perhaps with the result of increasing the
purity of a select product gas, increasing the BTU value of a
select product gas, or perhaps minimizing contaminants within a
select product gas. In various embodiments, such resulting products
may be considered to be separation products resulting from the act
of selectively separating as described herein.
[0079] A gasifier process flow path in various embodiments may be
routed through a multiple coil carbonaceous reformation vessel (19)
(FIGS. 1; 2; 3; 4; 14). For example, a process flow may include
pyrolytically decomposed carbonaceous materials from a pyrolysis
chamber, perhaps such as released gas and carbon-bearing
particulate matter pressurized out of a temperature varied
environment. A multiple coil reformation vessel may include two or
more reformation coils through which a process flow may be routed.
Carbonaceous materials entrained in the process flow may be
reformed within each such reformation coil. Such carbonaceous
reformation may encompass perhaps simply changing the form of such
carbonaceous materials, as for example perhaps from or into select
product gas components, from or into incompletely reformed
carbonaceous materials, from or into ash, or perhaps from or into
various types of contaminants. In some embodiments, carbonaceous
reformation may involve vaporizing a carbonaceous material, for
example such as vaporizing hydrocarbons or vaporizing select
product gas components. Moreover, reformation coils perhaps may
simply provide a coiled path through which a process flow may be
routed during a carbonaceous reformation stage in a solid
carbonaceous materials gasifier system, in some embodiments for
example as perhaps through a coiled tube, pipe, conduit, or the
like. A multiple coil carbonaceous reformation vessel may include a
preliminary reformation coil, a secondary reformation coil, a
tertiary reformation, and perhaps one or more additional
reformation coils as may be desired to achieve carbonaceous
reformation.
[0080] Embodiments may include complementarily configuring at least
two reformation coils, which may involve positioning the
reformation coils relative to each other to improve the efficacy of
the carbonaceous reformation process. For example, some embodiments
may involve helically nesting at least two carbonaceous reformation
coils. Such a helically nested arrangement perhaps may improve the
efficacy of the carbonaceous reformation process by reducing the
size occupied by a multiple coil carbonaceous reformation vessel,
or perhaps by permitting the selective distribution of heat applied
to the helically nested configuration, such as wherein heat may be
applied to one coil and radiated from that coil to another
helically nested coil. In this manner, individual reformation coils
may be seen to act as radiators. For example, embodiments may
involve a preliminary reformation coil, a secondary reformation
coil, and a tertiary reformation coil in a helically nested
configuration, wherein heat applied to the helically nested
configuration may be variably triply distributed from one coil to
another, and the configuration may act as a tripart reformation
coil radiator. Of course, it may be appreciated that the manner in
which two or more reformation coils may be complementarily
configured and the location and modality in which heat may be
selectively applied may create a variety of arrangements that may
represent selectively adjustable process control parameters,
perhaps even dynamically adjustable process determinative
parameters.
[0081] For example, in some embodiments, a horizontal helically
nested configuration of multiple reformation coils such as one
inside the other may be applied. Such a configuration may provide a
high temperature helical coil reformation environment that may
establish the longest length within the smallest cube design volume
space and footprint, perhaps as shown in assembly (19) and
embodiments (15), (16) & (18) (FIGS. 1; 2; 3; 4; 5; 6; 7; 14).
As one example, assembly (19) may have a nesting configuration
design that may provide an extremely efficient heat transfer
cubical unit whereby the maximum amount of helical reformation coil
lineal footage of pipe is packed into the smallest cubic volume of
box furnace enclosure (26) (FIGS. 1; 2; 13; 14) space. This
configuration may provide radiant heat transfer from the outermost
coil (18) (FIGS. 1; 2; 5; 6; 7; 14) to the innermost coil (15)
(FIGS. 1; 2; 5; 6; 7; 14) and vice versa. This may reduce an
overall furnace BTU combustion heat and the input select product
gas energy requirement as necessary such as perhaps to hold the
furnace temperature constant in the 1,600.degree. F. to
1,800.degree. F. temperature range.
[0082] The helical reformation coil assembly (19) inside of the
furnace may be heated and held at an elevated level, perhaps such
as from about 1,600.degree. F. to about 1,800.degree. F. Further,
the furnace may be heated by a computerized and auto-controlled
combustive burner manifold system (14) (FIGS. 1; 2; 14; 9). A
combustive burner may utilize recycled select product gas as the
combustible fuel source, perhaps with an alternate connection to an
external fuel source, perhaps a pressurized propane tank, to be
supplied as an initial startup fuel source or the like. In the
helical reformation coil assembly 19, a burner manifold forced air
combustion system may hold the temperature of all three reformation
coils (15), (16) and (18) (FIGS. 1; 2; 5; 6; 7; 14) elevated,
perhaps such as at a minimum of about 1,600.degree. F. in order to
facilitate carbonaceous reformation, as for example where
substantially all atomized carbon particulate material moving
through the combined length of all three reformation coils may be
substantially completely carbonaceously reformed (perhaps such as
in the presence of steam) into select product gas components, such
as perhaps carbon monoxide and hydrogen gases. In embodiments, a
combustive burner manifold system (14) (FIGS. 1; 2; 14) may be
placed on the inside of the box furnace enclosure (26), for example
perhaps at the bottom inside wall and perhaps further extended
one-third upward on two opposing sidewalls (not shown). Burner
jet-nozzles may penetrate through the box furnace enclosure (26)
(FIGS. 1; 2; 13; 14), perhaps with pressure-tight weldments, and
perhaps may further penetrate through a perhaps twelve inch
thickness of high temperature glass wool insulation (perhaps with
ceramic heat shield cones placed around each burner jet-nozzle
pipe). Nozzles may be strategically angle positioned to produce a
selectively applied heat distribution, such as perhaps an evenly
distributed blanket of heat across the entire reactor embodiment
surfaces (and perhaps throughout the three-dimensional helical nest
structure) of the helical reformation coil configuration (19)
(FIGS. 1; 2; 3; 4; 14). To provide maximum heat and strength
longevity, the reformation coils (15), (16) and (18) (FIGS. 1; 2;
5; 6; 7; 14) may be fabricated from high strength and high
temperature Inconel.RTM. or other such metal pipe, or other
alternate and appropriate metallic materials. Reformation coil
(such as per each nesting coil) diameters may vary from about three
inches to about eight inches in diameter and the pipe lengths may
vary proportionally as dependent upon the daily tonnage of input
feedstock volume that is to be processed, perhaps in order to
maintain optimum process gas velocity throughout the multiple
carbonaceous reformation coil vessel and any selective separators
incorporated therein.
[0083] Operating conditions of a preliminary reformation coil,
perhaps as exemplified within helical reformation coil assembly
(19), may include an operating condition of at least 50 psi to 100
psi, 1,640.degree. F. to 1,800.degree. F., and a flow rate from
5,000 fpm to 20,000 fpm. Similarly, operating conditions of a
secondary reformation coil, perhaps as exemplified within helical
reformation coil assembly (19), may include an operating condition
of at least 50 psi to 100 psi, 1,640.degree. F. to 1,800.degree.
F., a flow rate from 5,000 fpm to 20,000 fpm, and perhaps a
reformation time of up to about 5 seconds. Moreover, operating
conditions of a tertiary reformation coil, perhaps as exemplified
within helical reformation coil assembly (19), may include an
operating condition of at least 50 psi to 100 psi, 1,750.degree. F.
to 1,850.degree. F., a flow rate from 5,000 fpm to 20,000 fpm, and
perhaps a reformation time of up to about 4 seconds. Total
reformation time of a multiple coil carbonaceous reformation
vessel, again as perhaps exemplified by helical reformation coil
assembly (19), may be from about 4 seconds to about 10 seconds.
[0084] Moreover, embodiments may include adding reaction beneficial
materials to at least one reformation coil of a multiple coil
reformation vessel, for example such as adding before a preliminary
reformation coil, adding between a preliminary reformation coil and
a secondary reformation coil, adding between a secondary
reformation coil and a tertiary reformation coil, adding after a
tertiary reformation coil, utilizing a venturi injector, utilizing
a flue gas, utilizing a pressurized flue gas, utilizing a preheated
flue gas, and perhaps via a reaction beneficial materials
input.
[0085] Carbonaceously reforming within a multiple coil carbonaceous
reformation vessel in various embodiments may include selectively
separating carbonaceous materials at various points within the
vessel with a carbonaceously reformed materials selective
separator, for example perhaps via vortex action using a cyclone.
One or more selective separators perhaps may be employed and placed
at suitable locations within the multiple coil carbonaceous
reformation vessel, for example perhaps to achieve selective
separation before a preliminary reformation coil, between a
preliminary reformation coil and a secondary reformation coil,
between a secondary reformation coil and a tertiary reformation
coil, and perhaps after a tertiary reformation coil. Selectively
separating in this manner perhaps may allow progressive refinement
of a quality of a carbonaceous material as it is routed through the
reformation coils of a multiple coil reformation vessel, for
example, perhaps by progressively reducing the particle size of
carbonaceous particles transiting from coil to coil. Moreover, such
selectively separated carbonaceous materials may be recycled, for
example via a carbonaceously reformed materials recycle path, to
any suitable gasifier process flow path location, such as a
pretreatment area, a pyrolysis chamber, a preliminary reformation
coil, a secondary reformation coil, and perhaps by utilizing a
venturi injector, utilizing a flue gas, utilizing a pressurized
flue gas, utilizing a preheated flue gas, or the like.
[0086] In some embodiments, for example, a cyclone (20) (FIGS. 1;
2; 14) perhaps may be fitted to an end outlet of a preliminary
reformation coil (15) (FIGS. 1; 2; 5; 6; 7; 14). Such a cyclone may
be fabricated from high temperature Inconel.RTM. or other alternate
and appropriate metallic materials or the like. In embodiments, a
cyclone perhaps may be engineered to remove carbonaceous materials,
such as perhaps the majority of char carry-through particulate
material such as that is about 80 to about 150 microns in particle
size, or larger. A venturi, perhaps a venturi injector, may be
joined at the cyclone bottom exit port, and perhaps may control a
periodic emptying of accumulated selectively separated carbonaceous
materials, perhaps such as char debris, for recycling back such as
into a pyrolysis chamber. Such recycling perhaps may allow
additional pyrolytic decomposition of the recycled carbonaceous
material, for example carbon containing char particulates, to
occur. The venturi, perhaps a venturi injector, may be provided
with a side-stream injection port from a produced select product
gas delivery manifold (21) (FIGS. 1; 2; 8; 9; 14) and may also
provide perhaps a variable differential pressure that may assist in
clearing the cyclone of selectively separated carbonaceous
material. Moreover, a venturi injector unit (17) (FIG. 3) may be
connected, perhaps flange connected, to the top outlet of the
cyclone (20), and perhaps may utilize nuclear industry design high
temperature flexatalic gaskets and bolt assemblies. A venturi
injector (17) further may be connected, perhaps flange connected,
such as to an inlet opening of a secondary reformation coil (16)
(FIGS. 1; 2; 5; 6; 7; 14) and perhaps may provide additional
turbulent flow steam reformation into the reformation coil
(16).
[0087] A carbonaceous materials selective separation sequence
perhaps may be repeated for a secondary reformation coil, perhaps
relative to applying a cyclone (22) (FIGS. 1; 2; 14). A cyclone
(22) may act to remove carbonaceous materials, perhaps such as
carry-through char particulates down to about 50 to about 130
microns in particle size, perhaps by connecting, perhaps flange
connecting, the cyclone from an exit opening of the secondary
reformation coil (16) (FIGS. 1; 2; 5; 6; 7; 14) to the entry
opening of the tertiary reformation coil (18) (FIGS. 1; 2; 5; 6; 7;
14). A venturi injector (17) (FIG. 1; 2; 8; 9; 14) may be also
installed, as perhaps within pipe flange connections between the
top exit of the cyclone classifier (22) and the entry point into
the tertiary reformation coil (18). This additional installed
location of a venturi injector (17) (FIG. 1; 2; 8; 9; 14) may
further provide accelerated carbonaceous reformation, perhaps to
additionally decrease CO.sub.2 and other hydrocarbon concentrations
in the select product gas stream being generated. As with the
cyclone (20) (FIGS. 1; 2; 14), a bottom exit venturi, perhaps
venturi injector possibly with recycled select product gas
side-stream injection, may be provided that may work on
differential pressure to periodically empty selectively separated
carbonaceous material, such as char particulate material, perhaps
recycled back such as into the pyrolysis track feeder or into a
preliminary reformation coil. This may provide for the recycle
recovery of carbonaceous materials, perhaps such as most all char
organic carbon content, perhaps via the re-processing of recovered
char particulate material within a preliminary reformation
coil.
[0088] Two cyclones (23) (FIGS. 1; 2; 14), perhaps tertiary final
polish cyclone classifiers, may be included and may be connected,
perhaps flange connected, to an exit opening such as of a tertiary
reformation coil (18) (FIGS. 1; 2; 5; 6; 7; 14). These perhaps may
be provided as pipe arrangements in series with each other, and
perhaps may selectively separate and remove any remaining
carbonaceous materials or ash carry-through particulate material,
for example perhaps in the particle size removal ranges of: 10% of
1 micron size particles being removed; 25% of 2 micron size
particles being removed; 35% of 3 micron size particles being
removed; and even 100% of 15 micron size (or above particle size)
particles being removed. In embodiments, two series-staged
polishing cyclones (23) may be utilized perhaps to ensure that any
possible post contamination of carbonaceous materials, such as
perhaps still reactive char materials, or ash substrate carrying
through to contaminate final produced select product gas may be
avoided. Further, an ash removal system, perhaps such as an
auto-purge double air-lock valve system, may be employed such as to
perhaps periodically empty any fine ash particulate material from
such cyclones into an ash receiver system and automated removal
section.
[0089] A gasifier process flow path in various embodiments may be
routed through an ash removal area (78) (FIGS. 1; 2) of a solid
carbonaceous materials gasifier system. This may be illustrated
conceptually in one embodiment in FIGS. 1 & 2. In embodiments,
fine particulate material perhaps may pass through a multiple coil
carbonaceous reformation vessel. This fine particulate material may
be substantially, perhaps even 95% or more, selectively separated
via cyclones (23) (FIGS. 1; 2; 14). The majority of these
selectively separated fine particulate materials may be inert and
may exist as non-carbon and non-reactive ash substrate. Such ash
substrate material may be selectively separated from the gasifier
process flow path perhaps to eliminate nearly all particulate
contamination and perhaps to ensure that a high quality purity of
the final select product gas is maintained.
[0090] An ash removal handling system, perhaps airtight and
pressurized, may be provided whereby two cyclones (23) (FIGS. 1; 2;
14) each may empty collected ash, perhaps via a sealed conduit pipe
connection through a box furnace enclosure (26) (FIGS. 1; 2; 13;
14), and perhaps such as into smaller ash receiver tanks (24)
(FIGS. 1; 2; 15). The ash may be withdrawn from the two cyclones
perhaps through a dual airlock and triple, perhaps slide actuation,
valve system (7) (FIGS. 1; 2; 15). In embodiments, as the top and
bottom valves may actuate to the open position, the middle valve
may remain closed. Intermittently, hot ash may fall by gravity into
the top receiver tank and the bottom receiver tank (24) (FIGS. 1;
2; 15). Ash from the bottom receiver tank (perhaps somewhat cooled)
may fall down and into an elliptical conveyor screw trough and
separated ash recovery unit (25) (FIGS. 1; 2; 15) perhaps to be
subsequently transported to adjacent mobile storage, perhaps
cooling bins. Valves, such as slide valves (7) may be air-operated
and may cycle open and closed on a reciprocal time basis perhaps
such as perhaps approximately every 30 minutes or as controlled by
process computer set-points. Adjustable time frequency of valve
actuation may provide for additional ash cooling time to occur
within the ash receiver tank (24). Further, ash receiver tanks and
even the slide valve assemblies may be constructed of high
temperature steel materials. The removed ash, perhaps as dependent
upon the input carbonaceous feedstock chemical composition, may
represent an item with resale potential as a high grade mineral
fertilizer additive, and perhaps may be applied as a cementaceous
filler in cement construction block manufacturing operations.
[0091] A solid carbonaceous materials gasifier system in various
embodiments may generate a contaminated select product gas. Such
contaminants may include perhaps simply any substances tending to
reduce the quality of a select product gas. Examples of such
contaminants may include for example chemical by-products, thermal
by-products, pyrolytic decomposition by-products, carbonaceous
reformation by-products, carbon dioxide, carbonate, insoluble
solids, tar, phenol, hydrocarbon, and other particulates.
Accordingly, embodiments may provide for isolating a significant
number of contaminants and creating a scrubbed select product gas.
This may be illustrated conceptually in process embodiments in
FIGS. 1& 2. Such isolation may be accomplished in any suitable
manner consistent with the principles discussed herein, for example
perhaps by pyrolysis, screening, magnetism, vortex action, or the
like. In some embodiments, such isolation may be accomplished by
solubilizing the contaminants in a contaminant solubilization
substance, perhaps as may be disposed within a select product gas
components scrubber through which said gasifier process flow path
may be routed. Such solubilization further may comprise increasing
the purity of a select product gas, increasing the BTU value of a
select product gas, minimizing contaminants within a select product
gas, or perhaps even creating a scrubbed select product gas having
one or more of these properties, consistent with the principles
described herein.
[0092] A contaminant solubilization substance in certain
embodiments may include a negatively electrostatically enhanced
water species. Contaminant isolation may occur upon solubilization
of contaminants in such a negatively electrostatically enhanced
water species, perhaps via an oxidation reaction, a reduction
reaction, an adsorption coagulation reaction, an absorption
coagulation reaction, or the like. Accordingly, such solubilization
may involve coagulating, separating, flocculating, precipitating,
settling, condensing, polishing, filtering, removing via final
polarized media polish filtration, and removing via
electro-precipitation removal such contaminants.
[0093] Contaminant solubilization substances also perhaps may
include chilled contaminant solubilization substances. For example,
embodiments may include lowering the temperature of a select
product gas via a chilled contaminant solubilization substance in a
select product gas components scrubber, for example as from greater
than about 1700.degree. F. to less than about 175.degree. F.
Moreover, such use of a chilled contaminant solubilization
substance to lower the temperature of a select product gas may
prevent vitrification solidification of contaminants within the
select product gas as it is cooled, with contaminants instead
perhaps being solubilized in the contaminant solubilization
substance with decontaminated select product gas being maintained
in an unvitrified state.
[0094] Moreover, a select product gas components scrubber in
various embodiments may include at least a primary solubilization
environment and a secondary solubilization environment, for example
perhaps a primary scrubber tank and a secondary scrubber tank. Such
multiple solubilization environments perhaps may provide multiple
stage scrubbing of a select product gas, for example as wherein one
scrubbing stage may be insufficient to accomplish a desired level
of scrubbing, or as wherein it may be desirable to spread various
scrubbing steps over several stages, such as perhaps for reducing a
temperature of a select product gas being scrubbed. For example,
primarily solubilizing in a primary solubilization environment in
some embodiments perhaps may be configured to lower a temperature a
select product gas from greater than 1,700.degree. F. to less than
550.degree. F., and secondarily solubilizing in a secondary
solubilization environment perhaps may be configured to lower a
temperature a select product gas from greater than 450.degree. F.
to less than 150.degree. F. Of course, multiple stage scrubbing may
address other process parameters, for example as wherein a primary
solubilization environment may be configured to remove 70% to 80%
of contaminants from a select product gas, with a second
solubilization environment configured to remove perhaps some
additional fraction of remaining contaminants.
[0095] Accordingly, embodiments may involve mixing and injecting
one or more negatively electrostatically enhanced water species,
such as perhaps a large portion of ionized and perhaps highly
reactive oxygen vapor gases perhaps utilizing singlet oxygen, into
a select product gas components scrubber through which a gasifier
process flow path may be routed. Contaminants entrained in the
gasifier process flow path perhaps may then be solubilized into the
water species. Such contaminants perhaps may be further removed
from the water species in one or more of several separating devices
which may be incorporated into the select product gas components
scrubber. In such arrangements, negatively electrostatically
enhanced water species and hot synthesis gas reaction contact may
take place. Coalescence and oxidation of contaminants may occur and
may cause CO.sub.2 (perhaps oxidized to CO.sub.3 agglomerates),
insolubles, tars, phenols, and other hydrocarbon contaminants to
flocculate, precipitate, and/or perhaps settle for final polarized
media polish filtration electro-precipitation removal of said
contaminants.
[0096] Moreover, embodiments of the inventive technology may
provide additional select product gas final purification and
cleanup systems. Some of these may be as specifically indicated in
the depiction of an embodiment such as shown in a scrubber area
(79), (FIGS. 1; 2; 16), which may include (but may not require)
elements as follows: [0097] element (27): an Insulated Crossover
Pipe (perhaps 1800.degree. F. Synthesis Gas) To Scrubber Tank Inlet
Cylinder, [0098] element (28): a Mix (perhaps Synthesis
Gas/VIP.TM./Ionized Water) Injector Cylinder, [0099] element (29):
a VIP.TM. (Vapor Ion Plasma) Ionized Water And Synthesis Gas
Primary Scrubber Tank With Temperature Reduction perhaps To
350.degree. F., [0100] element (30): a VIP.TM. Ionized Water Spray
Manifold, [0101] element (31): a VIP.TM. Vapor Ion Plasma
Generator, [0102] element (32): a VIP.TM. Injection Ionized
H.sub.2O Spray Diffusers, [0103] element (33): a Recirculation Flow
(perhaps Doubled Walled) Tank and chilled water separation tank,
such as for Tar/Phenols Drop-Out, [0104] element (34): an
Auto-Control H.sub.2O Balance Valves, [0105] element (35): a
VIP.TM. Ionized Water and Synthesis Gas Secondary Scrubber Tank,
such as for Final Hydrocarbon(s) Removal, [0106] element (36): a
Scrubber H.sub.2O Recycle Recirculation Pump, [0107] element (37):
a VIP.TM. Cooling H.sub.2O Return Manifold, [0108] element (38): a
Chilled Water Tank (Tars/Phenols) Bleed-Off Return perhaps As
Recycle Recovery Back To a pyrolytic decomposition area (75) Track
Feeder Devolatilization Zone, or perhaps To Be Separated In an
auxiliary treatment area (76) Roto-Shear.TM. Concentrator Unit,
[0109] element (39): a Synthesis Gas (perhaps 350.degree. F.
Crossover) Pipe To Secondary Scrubber Tank, [0110] element (40): a
(perhaps Auto-Controlled) Temperature Chiller, [0111] element (41):
an Air/Liquid perhaps Serpentine Heat Exchanger, [0112] element
(42): a Delivery (perhaps 80.degree. F.) Manifold To electrically
filter (eFILT.TM.) perhaps via a Polarized Media Filter, [0113]
element (43): an eFILT.TM. (perhaps Polarized Media Filter)
Recirculation Pump, [0114] element (44): an eFILT.TM. Influent
Filtration Manifold, [0115] element (45): an eFILT.TM. perhaps
Polarized Media Filter, Per Fine (perhaps One Micron Particle Size)
Solids Removal, Including "CO.sub.2 Shift To CO.sub.3" Removal,
[0116] element (46): a VIP.TM. Ionized H.sub.2O and Solids Slurry
By-Pass Line to Embodiment (51), [0117] element (47): a Filtered
VIP.TM. perhaps Ionized H.sub.2O Recycle Return To Primary Scrubber
Tank, [0118] element (48): an eFILT.TM. Backwash Water To Holding
and Settling Tank, [0119] element (49): a Backwash H.sub.2O Slurry
Holding and Settling Tank, [0120] element (50): a Recirculation
Chilled Water Separation Tank Overflow, [0121] element (51): a
Common (VIP.TM./Ionized H.sub.2O/Solids) Return To Track Feeder
Injection, [0122] element (52): a Synthesis Gas Side-Stream
Manifold Feed To Reactor Combustion Burner, [0123] element (54): a
Polish (H.sub.2O Removal) Coalescer and Condenser, [0124] element
(55): a Polish Synthesis Gas (Fine Micron) Filters, [0125] element
(56): a Backwash Solids Roto-Shear (rS.TM.) Screw Concentrator and
Separator, [0126] element (57): a Scrubber Tank Level Indicator and
Controller, [0127] element (58): a System Components Overflow Drain
Line, element (59): an Overflow Holding Tank and a VIP.TM. Ionized
H.sub.2O and Backwash H.sub.2O Collection Tank, [0128] element
(60): a Synthesis Gas Delivery Compressor, [0129] element (61): a
Drain Line To Systems Collection Receiver Flash-Evaporator Unit,
[0130] element (62): a VIP.TM. Ionized H.sub.2O Pump, [0131]
element (63): an Outside Makeup Water Line, [0132] element (64): a
Filter Backwash Water Input Line, [0133] element (65): a
Concentrated Solids Transfer To (perhaps External) Recovery Unit,
[0134] element (69): a Final CO.sub.2 Separation (perhaps Molecular
Sieve Unit) if required, [0135] element (70): a Final Output Highly
Purified [perhaps 550 BTU to 650 BTU] Synthesis Gas (perhaps
Stripped of NO.sub.X, SO.sub.X, CO.sub.2 and Organic Vapors)
Stream, [0136] element (71): a Safety (perhaps Auto-Pressure)
Relief Valve, [0137] element (72): an External Flare (perhaps
Auto-Ignition) System, and [0138] element (73): a VIP.TM. Ionized
H.sub.2O and Solids Slurry Pump.
[0139] In various embodiments, at least some isolated contaminants
may be recycled within a solid carbonaceous materials gasifier
system and reprocessed therein. Accordingly, embodiments may
involve returning such isolated contaminants, for example via a
contaminants recycle path appended to a select product gas
components scrubber and returning to a contaminants recycle input
of a gasifier process flow path. Moreover, such recycling may
involve selecting a recycle path, perhaps as from a multiply
routable path. Such a multiply routable path in some embodiments
may be routed through a feedstock solids carbonaceous materials
processor, a select product gas components scrubber, a contaminants
recycle path, and a contaminants recycle input of a gasifier
process flow path. Moreover, in various embodiments, routing a
contaminants recycle path to a contaminants recycle input may
involve routing to a recycle input of a pretreatment area,
pyrolysis chamber, multiple coil carbonaceous reformation vessel,
preliminary reformation coil of a multiple coil carbonaceous
reformation vessel, secondary reformation coil of a multiple coil
carbonaceous reformation vessel, or a tertiary coil of a
carbonaceous reformation vessel. Additionally, a contaminants
recycle path in various embodiments may include a venturi, or
perhaps even a venturi injector, for example perhaps to assist in
moving contaminants through the recycle path.
[0140] Various embodiments may include a select product gas
components formation zone through which a gasifier process flow
path is routed. Consistent with the principles described herein,
such a select product gas components formation zone perhaps simply
may be any portion of a gasifier process flow path in which select
product gas components may be formed. For example, processing
stages tending to generate carbon monoxide content select product
gas components, hydrogen content select product gas components, or
perhaps controlled molar ratio select product gas components may be
select product gas components formation zones in various
embodiments. Moreover, embodiments also may include a select
product gas formation zone. Again, consistent with the principles
described herein, such a select product gas formation zone perhaps
simply may be any portion of a gasifier process flow path in which
a select product gas may be formed. Of course, such a select
product gas may include any of various characteristics as described
elsewhere herein.
[0141] A gasifier process flow path in various embodiments may be
routed through a product gas combustion preparation auxiliary
treatment area (76) (FIGS. 1; 17). Embodiments may provide the
return of a side-stream of produced select product gas, perhaps
combustible 550 BTU to 650 BTU per pound, perhaps as from a
produced select product gas outlet conduit pipe (52) (FIGS. 1; 2)
to a combustive burner (14) (FIGS. 1; 2; 14). This may further
extend from the produced gas outlet pipe (52) to provide an
optional select product gas feed to a venturi feed pipe (53) (FIGS.
1; 2; 17), perhaps a venturi injector, providing inlet access to a
multiple coil carbonaceous reformation vessel or the like.
Combustion sustaining operations fuel may be autonomously provided
by a recycle return, perhaps at a level of 15% or less of the total
select product gas volume being generated.
[0142] Embodiments may include an air separation unit (66) (FIGS.
1; 2; 17), perhaps including an air intake and a nitrogen depletion
area to deplete at least some nitrogen from taken in air. In this
manner, a supply of enriched oxygen air flow may be generated and
nitrogen content perhaps may be reduced within a solid carbonaceous
materials gasifier system. For example, an oxygen enrichment line
may be routed to a combustive burner whereby oxygen concentration
input may be increased, for example perhaps such as by
approximately 30%, which may in turn reduce a recycle requirement
of select product gas such as to support furnace combustion
operational temperatures, at a level of perhaps less than 10% of
the recycle requirement. Moreover, an air separation unit (66)
(FIGS. 1; 2; 17) may greatly deplete the nitrogen content in a
combustion air intake stream, for example as may supply combustion
operations at one or more combustive burners, which may
substantially reduce process carry-through of nitrogen contaminants
into the gasifier process flow path, including perhaps the final
produced select product gas. Nitrogen oxides contamination and
emission possibilities may be greatly reduced, eliminated, or may
even become virtually non-existent. A combustion adjustable baffle
proportioning flow air fan (67) (FIGS. 1; 2; 17) may be provided to
meter atmospheric air intake, with recycled select product gas
(perhaps with air separation unit (66) enriched oxygen air flow),
perhaps as a forced draft combustible admixture gas flow into a
combustive burner (14). Additionally, a side-stream oxygen
enrichment line (68) (FIGS. 1; 2; 17) may be connected, perhaps as
a bypass pipe connection, to a negatively electrostatically
enhanced water species generation unit, for example perhaps one or
more VIP.TM. Vapor Ion Plasma generator units (31) (FIGS. 1; 2; 10;
16). The input addition of a more concentrated oxygen addition to
such units, for example such as an activated oxygen content, may
greatly enhance the output of negative electrostatic enhancement
species, for example perhaps vapor ion plasma singlet oxygen or
peroxyl ion concentrations as injected into an ionized oxygen water
stream, as may be applied throughout a solid carbonaceous materials
gasifier system in various embodiments. Accordingly, embodiments
may provide for a nitrogen depleted select product gas, which in
fact may be a nitrogen oxide content minimized select product gas,
a purified select product gas, or even a high BTU content select
product gas.
[0143] A solid carbonaceous materials gasifier system in various
embodiments may subject to an input feedstock solids carbonaceous
material to a variety of chemical reaction sequences. A basic
chemical reaction sequence often considered in the production of
synthesis gas may be represented in Table 1 as follows, though the
inventive technology may be applicable to a variety of chemical
reaction sequences and should not be considered as limited to just
the following:
TABLE-US-00001 TABLE 1 ##STR00001##
[0144] In some embodiments, process determinative parameters of the
inventive technology may permit manipulation of this and other
chemical reaction sequences, and indeed perhaps even non-chemical
processing aspects, in a solid carbonaceous materials gasifier
system to generate high energy content, purified, or even high
yield select product gas, perhaps such as by finishing the chemical
reaction sequence to substantial completion for a majority of or
perhaps substantially all of the carbon content in a feedstock
solids carbonaceous material. For example, embodiments may involve
dynamically adjusting at least one such process determinative
parameter, as perhaps with a dynamically adjustable process flow
regulator. The dynamic character of such an adjustment may stem
from the capability of effecting such adjustments while the
gasifier system is operating. For example, embodiments may include
sensing at least one process condition with a process condition
sensor and adjusting at least one process determinative parameter
with a sensor responsive dynamically adjustable flow regulator
based on the sensed condition. Sensing, of course, may be
accomplished in any of a variety of suitable manners, such as
sensing a temperature, sensing a pressure, sensing a process
materials composition, sensing a carbon monoxide content, sensing a
carbon dioxide content, sensing a hydrogen content, sensing a
nitrogen content, sensing a sulfur content, sensing via a gas
chromatograph, sensing via a mass spectrometer, and the like.
Similarly, any of a variety of adjustments may be dynamically
affected in response by an appropriate process flow regulator, such
as suitable inputs, injectors, separators, returns, timers, and the
like. Examples of such adjustments may include adding water, adding
preheated water, adding recycled water, adding a negatively
electrostatically enhanced water species, adding a preheated
negatively electrostatically enhanced water species, adding a
recycled negatively electrostatically enhanced water species,
adding steam, adding recycled steam, adding negatively
electrostatically enhanced steam, adding recycled negatively
electrostatically enhanced steam, adding flue gas, adding preheated
flue gas, adding pressurized flue gas, adding recycled flue gas,
adding a recycled incompletely pyrolytically decomposed
carbonaceous material, adding a recycled incompletely reformed
carbonaceous material, adding at least one recycled contaminant,
adding at least some select product gas, adding at least some wet
product gas, adding at least some dry select product gas, adding at
least some recycled select product gas, varying a process retention
time, varying a process flow rate, varying a process flow
turbulence, varying a process flow cavitation, varying a
selectively applied heat distribution among multiple reformation
coils, varying a temperature gradient in a temperature varied
environment, varying a liquefaction zone in a temperature varied
environment, selectively separating a carbonaceously reformed
material, and the like. In some embodiments, these parameters may
be process determinative in that their adjustment may affect and
therefore perhaps determine the outcome of solid carbonaceous
materials processing in the gasifier system.
[0145] Moreover, such dynamic adjustments may be effected at any
suitable point of a gasifier process flow path with an appropriate
input, including perhaps at a pretreatment area, at a pyrolysis
chamber, at a multiple coil carbonaceous reformation vessel, at a
select product gas components scrubber, and the like, perhaps even
as may be embodied in some embodiments in a modular section of such
a gasifier system. Additionally consistent with the dynamic
character of such adjustments, the adjustments perhaps may be
automatically effected, perhaps such as by computer control. Such
dynamic adjustments may permit fast response time implementation of
the adjustments, perhaps in times as little as less than 0.5
seconds, less than 1 second, less than 2 seconds, less than 3
seconds, less than 4 seconds, less than 5 seconds, less than 10
seconds, less than 15 seconds, less than 30 seconds, less than 45
seconds, less than 60 seconds, less than 90 seconds, and the
like.
[0146] Various embodiments of course may involve effecting these
dynamic adjustments in a variety of suitable modalities. For
example, embodiments may include establishing an adjustable set
point and periodically testing a process condition. Such a set
point may involve carrying out processing to a set specification,
such as a set time, temperature, pressure, or the like. In this
manner, periodically testing a process condition, for example by
measuring a processing time, temperature, pressure, or the like,
may allow determination of processing conditions relative to the
set point and appropriate dynamic adjustment if actual processing
conditions are off. Further examples of suitable modalities may
include evaluating a feedstock solids carbonaceous material, as
with perhaps a feedstock evaluation system, for example by
characteristics such as chemistry, particle size, hardness,
density, and the like, and responsively dynamically adjusting
process flow conditions accordingly. In some embodiments,
responsive dynamic adjustments may involve affecting a select
product gas, for example perhaps by increasing the purity,
increasing BTU content, reducing contaminants, or creating a select
product gas having one or more of these properties.
[0147] Embodiments may involve affirmatively establishing a
stoichiometrically objectivistic chemic environment. This perhaps
may involve establishing conditions, as within a pressurized
environment to which a feedstock solids carbonaceous material may
be subjected, having as an object the conversion of the feedstock
solids carbonaceous material into a desired product, for example
perhaps a desired select product gas. Such an environment of
courses may be chemic, which may involve chemical interactions in
which one or more components of the feedstock solids carbonaceous
material may participate, or perhaps even simply non-chemical
conditions related to such chemical interactions, for example such
as temperature conditions, pressure conditions, phase conditions,
or the like. Stoichiometric analysis may be utilized to
affirmatively identify significant relationships among the
components of the feedstock solids carbonaceous material and the
desired product, for example such as quantity amounts of such
components or perhaps chemical reaction sequences by which the
feedstock solids carbonaceous material may be converted into the
desired product. Where appropriate, stoichiometric compensation may
be utilized to add or remove chemical components according to the
identified relationships, for example perhaps to create an overall
balance of components in proportion to the identified
relationships. In various embodiments, stoichiometric compensation
may be accomplished in a solid carbonaceous materials gasifier
system via stoichiometrically objectivistic adjustment
compensators, for example such as any of various suitable inputs,
outputs, injectors, purges, dynamically adjustable process flow
regulators, and the like, consistent with the principles described
herein.
[0148] Some embodiments may involve stoichiometrically controlling
carbon content in a manner significantly appropriate for a select
product gas. This perhaps may involve applying the stoichiometric
principles described herein to the relationship between the carbon
content of a feedstock solids carbonaceous material and a carbon
content of an object select product gas to be produced. For
example, such stoichiometric applications may involve changing
carbon quantities through various processing stages of a solid
carbonaceous materials gasifier system. Processing may involve
adding carbon content throughout a gasifier process flow path, such
as to ensure sufficient quantities of carbon for complete
interaction with other processing materials throughout the various
processing states of the solid carbonaceous materials gasifier
system. An object may be to achieve a target carbon content in a
select product gas, for example perhaps according to the molar
ratios of chemical reaction sequences in which the feedstock solids
carbonaceous material may participate, or perhaps to achieve
desired molar ratios of carbon to other chemical components of the
object select product gas. Of course, this may be merely one
example as to how carbon content may be stoichiometrically
controlled, and should not be construed to limit the manner in
which stoichiometric control may be applied to carbon content
consistent with the principles described herein. Additional
examples of controlling carbon content may include adding carbon,
adding carbon monoxide, adding flue gas, adding pressurized flue
gas, adding preheated flue gas, adding an incompletely
pyrolytically decomposed carbonaceous material, adding an
incompletely reformed carbonaceous material, adding at least some
select product gas, adding at least some wet select product gas,
and adding at least some dry select product gas. Moreover, a
stoichiometrically objectivistic adjustment compensator in various
embodiments of course may include a stoichiometrically
objectivistic carbon adjustment compensator.
[0149] Affirmatively establishing a stoichiometrically
objectivistic chemic environment in some embodiments perhaps may
involve simply varying an input feedstock solids carbonaceous
material, perhaps as described elsewhere herein. Similarly, such
establishing perhaps may involve simply varying an output select
product gas, as in perhaps varying the select product gas qualities
perhaps described elsewhere herein. Variations of input and output
in this manner of course may vary the relationships among the input
and output materials, perhaps creating suitable opportunity for
application of the stoichiometric principles discussed herein.
[0150] In some embodiments, affirmatively establishing a
stoichiometrically objectivistic chemic environment may involve
selecting a product gas to output, evaluating a feedstock solids
carbonaceous material input, and determining a chemical reaction
sequence appropriate to yield the select product gas from the
feedstock solids carbonaceous material. Evaluating a feedstock
solids carbonaceous material of course may employ a stoichiometric
evaluation, for example such as identifying proportions,
quantities, and chemistry of constituent components of the
feedstock solid carbonaceous material, perhaps even as may be in
relation to possible chemical reaction sequences appropriate to
yield the select product gas. A suitable evaluation system may be
employed, for example such as a chemistry sensor, a temperature
sensor, a pressure sensor, a materials composition sensor, a carbon
monoxide sensor, a carbon dioxide sensor, a hydrogen sensor, a
nitrogen sensor, a gas chromatograph, a mass spectrometer, or the
like. Moreover, embodiments further may involve supplying chemical
reactants on a stoichiometric basis, for example perhaps as in
sufficient to satisfy the molar ratios of a chemical reaction
sequence, sufficient to substantially completely chemically react
the feedstock solids carbonaceous material, sufficient to produce a
high output of select product gas, sufficient to temporally
accelerate said chemical reaction sequence, or perhaps to effect
other stoichiometrically objectivistic considerations. Supply of
such chemical reactants of course may be effected with an
appropriate stoichiometrically objectivistic chemical reactant
input, for example perhaps a molar ratio input, a feedstock
conversion input, a high output select product gas input, a
catalyst input, or the like.
[0151] A flue gas in various embodiments perhaps may be utilized to
affirmatively establish a stoichiometrically objectivistic chemic
environment. For example, interaction of the flue gas with the
chemic environment may create stoichiometrically objectivistic
conditions, for example as wherein carbon content within a flue gas
may contribute to stoichiometrically adjusting carbon levels within
the chemic environment. Of course, this example simply may be
illustrative of the stoichiometric properties of flue gas, and a
flue gas may facilitate affirmative establishment of a
stoichiometrically objectivistic chemic environment in other
manners. Moreover, the modalities by which such flue gas may be
stoichiometrically utilized may be consistent with principles
described elsewhere herein. For example, a flue gas may be
pressurized, perhaps to at least 80 psi. A flue gas may be
preheated, perhaps to temperatures appropriate for a given
processing stage such as at least 125.degree. F., at least
135.degree. F., at least 300.degree. F., at least 600.degree. F.,
or at least 1,640.degree. F. A flue gas may be recycled, perhaps
including recycling to a pretreatment area, recycling to a
pyrolysis chamber, recycling to a multiple coil carbonaceous
reformation vessel, recycling to a preliminary reformation coil of
a multiple coil carbonaceous reformation vessel, recycling to a
secondary reformation coil of a multiple coil carbonaceous
reformation vessel, or recycling to a tertiary coil of a multiple
coil carbonaceous reformation vessel. Moreover, the stoichiometric
use of a flue gas may be considered to affect at least one process
determinative parameter, perhaps as described elsewhere herein,
perhaps such as by raising a temperature, maintaining a pressure,
raising a pressure, chemically reacting, temporally accelerating a
chemical reaction sequence, displacing at least some oxygen content
from a feedstock solids carbonaceous material, displacing at least
some water content from a feedstock solids carbonaceous material,
affirmatively establishing a stoichiometrically objectivistic
chemic environment for said feedstock solids carbonaceous material,
and stoichiometrically controlling carbon content. Of course, the
stoichiometric use of a flue gas may be effected by a suitable flue
gas injector, consistent with the principles described herein.
[0152] In various embodiments, affirmatively establishing a
stoichiometrically objectivistic chemic environment may include
adding process beneficial materials and purging process superfluous
materials. Adding process beneficial materials perhaps may simply
involve adding materials to a process environment tending to
benefit stoichiometric conditions, for example such as supplying
materials to balance quantities in proportion to the molar ratios
of a chemical reaction sequence or perhaps adding materials to
induce or catalyze such chemical reaction sequences. Examples of
process beneficial materials may include but may not be limited to
carbon, hydrogen, carbon monoxide, water, preheated water, a
negatively electrostatically enhanced water species, steam,
negatively electrostatically enhanced steam, select product gas,
wet select product gas, and dry select product gas. Similarly,
purging process superfluous materials perhaps may simply involve
removing materials superfluous, or perhaps even deleterious, to
stoichiometric conditions, perhaps such as contaminants or even
excesses of process materials that perhaps may be better utilized
through recycling. Examples of purging process superfluous
materials may include but may not be limited to purging oxygen,
purging nitrogen, or perhaps even oxidizing metals and
electrostatically attracting such oxidized metals. Of course, such
adding and purging may be accomplished by any suitable input or
purge consistent with the principles described herein.
[0153] Some embodiments may involve affirmatively establishing a
stoichiometrically objectivistic chemic environment by using
recycling, perhaps as described elsewhere herein. The
stoichiometric principles in such embodiments may be the same as
have been described, with perhaps utilized materials simply being
recycled materials appropriately returned from various areas of a
solid carbonaceous materials gasifier system.
[0154] Affirmatively establishing a stoichiometrically
objectivistic chemic environment in certain embodiments may include
sensing at least one process conditions and dynamically adjusting
at least one process determinative parameter, perhaps as described
elsewhere herein. Such establishing in some embodiments also may
include evaluating a feedstock solids carbonaceous material and
responsively dynamically adjusting at least one process
determinative parameter, again perhaps as described elsewhere
herein. In some embodiments, affirmatively establishing a
stoichiometrically objectivistic chemic environment may involve
removing water from a feedstock solids carbonaceous material at a
water critical pass through, which perhaps may be a critical
temperature and pressure for a given feedstock solids carbonaceous
material at which water may pass out of the feedstock.
[0155] Certain embodiments may affirmatively establish a
stoichiometrically objectivistic chemic environment in multiple
stages. For example, such establishing may involve preheating a
feedstock solids carbonaceous material, controlling oxygen content
within the feedstock, as perhaps with an oxygen displacement
system, and pyrolytically decomposing the feedstock solids
carbonaceous material. Of course, this example may be merely
illustrative of how a stoichiometrically objectivistic chemic
environment may be established in multiple stages, and should not
be construed to limit the manner in which such multiple stage
establishment may be effected.
[0156] Various embodiments may involve affecting processing within
a solid carbonaceous materials gasifier system with negatively
electrostatically enhanced water species. For example, embodiments
may include injecting negatively electrostatically enhanced water
species into a gasifier process flow path, or perhaps even gasifier
system components through which the gasifier process flow path is
routed, perhaps by using a negatively electrostatically enhanced
water species injector, routing a gasifier process flow path by a
negatively electrostatically enhanced water species injector, and
the like. The injection of a negatively electrostatically enhanced
water species in such a manner perhaps may bring it into contact
with carbonaceous materials entrained in a gasifier process flow
path, including for example perhaps at a pretreatment area, a
pyrolysis chamber, a multiple coil carbonaceous reformation vessel,
a select product gas components scrubber, and the like.
[0157] In some embodiments, a negatively electrostatically enhanced
water species may include an aqueous solution having a net negative
charge, as perhaps having a negatively charged species content
exceeding a contaminant background demand for the negatively
charged species content. Examples of a negatively electrostatically
enhanced water species in various embodiments may include an
aqueous solution containing saturated hydrogen peroxide and
negatively charged oxygen, an aqueous solution containing saturated
hydrogen peroxide and singlet molecular oxygen, an aqueous solution
containing saturated hydrogen peroxide and hydroxide, an aqueous
solution containing saturated hydrogen peroxide and hydroxide
radicals, an aqueous solution containing long-chain negatively
charged oxygen species, a peroxyl activated aqueous solution, a
nitroxyl activated aqueous solution, an oxygenated aqueous
solution, an ionized oxygen vapor aqueous solution, and the
like.
[0158] A negatively electrostatically enhanced water species in
some embodiments perhaps may be preheated. Of course, preheating
may be accomplished in any suitable manner consistent with the
principles described herein, for example perhaps using a suitable
preheater, perhaps such as a combustive burner or electric heater.
In certain embodiments, a preheater for a negatively
electrostatically enhanced water species perhaps may be a gasifier
system process enclosure, such as perhaps a pyrolysis chamber
enclosure, a multiple coil carbonaceous reformation vessel
enclosure, or perhaps even a box furnace enclosure (26) (FIGS. 1;
2; 13; 14). Moreover, preheating a negatively electrostatically
enhanced water species of course may generate steam, perhaps
negatively electrostatically enhanced steam.
[0159] The manner in which a negatively electrostatically enhanced
water species may affect processing within a solid carbonaceous
materials gasifier system may be selected to achieve a desired
result, for example perhaps to increase the purity of a select
product gas, increase the BTU value of a select product gas,
minimize contaminants in a select product gas, and the like. Such
desired results may be considered to be, for example, injection
products following the injection of a negatively electrostatically
enhanced water species into a gasifier process flow path. Moreover,
the use of a negatively electrostatically enhanced water species in
this way perhaps even may be considered as one example of
dynamically adjusting a process determinative parameter. For
example, affecting processing perhaps may involve chemically
reacting a negatively electrostatically enhanced water species, as
perhaps with carbonaceous materials entrained in a gasifier process
flow path. In such embodiments, the negatively electrostatically
enhanced water species simply may be chemical reactant
participating one or more chemical reaction sequences with the
carbonaceous material, for example as to perhaps produce hydrogen
select product gas components, produce carbon select product gas
components, decrease hydrocarbon contaminants, increase carbon
monoxide, increase hydrogen gas, and the like. Moreover, utilizing
a negatively electrostatically enhanced water species as a chemical
reactant perhaps may involve using it as catalyst, for example
perhaps to temporally accelerate one or more chemical reaction
sequences, or perhaps even to maximize the yield of one or more
chemical reaction sequences. In some embodiments, such uses of a
negatively electrostatically enhanced water species even perhaps
may be part of affirmatively establishing a stoichiometrically
objectivistic chemic environment and stoichiometrically controlling
carbon content. Some embodiments may involve coactively utilizing a
negatively electrostatically enhanced water species with other
process materials, for example perhaps injecting a negatively
electrostatically enhanced coactively with a flue gas.
[0160] Accordingly, negatively electrostatically enhanced water
species may be use in a variety of processing application within a
solid carbonaceous materials gasifier system. In embodiments having
specific input feedstock solids carbonaceous materials chemistry,
adjustable volumes of selected negatively electrostatically
enhanced water species may be provided, for example such as more
reactive ionized oxygen water, and perhaps may be injected and
perhaps vapor released into a gasifier process flow path, as
perhaps into one or more carbonaceous reformation coils of a
multiple coil carbonaceous reformation vessel. This perhaps may
also cause additional thermal steam vapor-cavitation turbulence
reactions. The presence of a negatively electrostatically enhanced
water species in the gasifier process flow path may provide much
faster and more complete carbon conversion and steam reformation
reactions to occur, for example such as within a pyrolysis chamber.
Additionally, embodiments may have the capability to dynamically
adjust process determinative parameters that may achieve a
generation of optimum select product gas production energy ratios,
decrease of CO.sub.2 contamination, and increase or adjustment of
desired higher energy output ratios of hydrogen and carbon
monoxide, perhaps including the capability of process adjustments
to yield higher output percentage fractions of methane content.
[0161] Moreover, negatively electrostatically enhanced water
species may be recycled, perhaps to achieve nearly 100% recycling,
as perhaps in a closed loop process within a solid carbonaceous
materials gasifier system, and as to perhaps even exceed an
environmental standard for recycling such a negatively
electrostatically enhanced water species. In various embodiments,
such recycled negatively electrostatically enhanced water species
may be a recovered contaminant solubilization substance from a
select product gas components scrubber. Through recycling,
negatively electrostatically enhanced water species, such as
perhaps ionized and perhaps peroxide saturated water, may be
constantly provided to meet various process water control volume
requirements within the solid carbonaceous materials gasifier
system. For example, recycle uses of negatively electrostatically
enhanced water species may include recycling to a pretreatment
area, recycling to a pyrolysis chamber, recycling to a multiple
coil carbonaceous reformation vessel, solubilizing a flue gas in a
recycled negatively electrostatically enhanced water species,
re-solubilizing at least one contaminant in a recycled negatively
electrostatically enhanced water species, regenerating a negatively
electrostatically enhanced water species, and generating steam from
a negatively electrostatically enhanced water species
[0162] Within the select product gas components scrubber,
accelerated oxidizing and reducing negatively electrostatically
enhanced water species recycle applications, perhaps as in-situ
chemistry applications, along with chilled water condensing,
perhaps may be applied which may provide for the isolation of items
such as soluble tar, phenols, organic hydrocarbon vapors,
particulate contaminants, and perhaps even soluble CO.sub.2 and
sulfur removals from various select product gas components, perhaps
to produce a scrubbed select product gas. Recycled negatively
electrostatically enhanced water species, as perhaps from a select
product gas components scrubber, also may be used to scrub flue gas
to maintain flue exhaust gas environmental air quality at or near
zero discharge compliance, whenever flue gas may be discharged into
the atmosphere.
[0163] A negatively electrostatically enhanced water species may be
generated in various embodiments perhaps by a negatively
electrostatically enhanced water species generation unit. Such a
unit perhaps even may be integrated into a solid carbonaceous
materials gasifier system, such as perhaps to permit on-site
generation of negatively electrostatically enhanced water species
and direct communication with a gasifier process flow path. For
example, such a unit may be joined to a negatively
electrostatically enhanced water species injector of a select
product gas components scrubber. In embodiments, an initial
generation of perhaps ionized oxygen vapors may take place within a
negatively electrostatically enhanced water species generation
unit, perhaps a gas ionization cylindrical system (31) such as
shown in FIGS. 1; 2; 10; 11; 16. This may provide an efficient and
perhaps high rate production of reactive and activated oxygen and
ionized vapors. Such a unit in some embodiments may be a VIP.TM.
vapor ion plasma generator, although such should use not to be
taken to limit the inventive technology only to such embodiments.
The use of a negatively electrostatically enhanced water species
generation unit, again perhaps such as a VIP.TM., may refer to the
production of ionized oxygen, associated peroxyl vapor gas ions, or
the like. Such a negatively electrostatically enhanced water
species generation unit may provide an efficient contaminant
solubilization substance treatment unit. The components perhaps may
be optimized to generate a plethora of highly reactive singlet
oxygen species from oxygen in air. Such may occur under
circumstances also encouraging secondary recombination with water,
perhaps water vapor or steam vapor, such as to perhaps produce
additional hydroxide and hydrogen peroxide gas vapor ions. In
various embodiments, such as shown in FIGS. 10 & 11, a
negatively electrostatically enhanced water species generation unit
may include, but may not require, elements as follows: [0164]
element (84) LECTRON Power Supply Module [0165] element (85)
LECTRON "Plasma (Variable) Emission" Generator [0166] element (86)
(Air-Cooled) Aluminum "Spectral-Physics" Ionization Reactor [0167]
element (87) Primary Electronic power Supply Module [0168] element
(88) AIR-INTAKE (1.5'' Wide "Ring" Intake Air Filter (Atmospheric
Nitrogen/Oxygen Air as the Ambient Treatment Source) [0169] element
(89) VIP.TM. Generated Vapor Ion (Out-Take) Delivery Port [0170]
element (90) O.sub.2/O.sub.2/0-0/e/OH Gas Vapor Ions (also
generates H.sub.2O.sub.2 & Intermediate "Reaction By-Products"
of Above) [0171] element (91) Pump Injection ("Vortex Eduction")
Into Contaminated Water Flow [0172] element (92) 45 degree Return
Line Rotation [0173] element (93) Recirculation Flow Scrubber
(Vapor Spray) "Ionized H2O" contact tank [0174] element (94) 3''
Dia. Pipe Flange Connection [0175] element (95) 3'' Cross [0176]
element (96) 3''.times.2'' Reducing Tee [0177] element (97) 3''
Valve [0178] element (98) Drain [0179] element (99) (Optimal) Dual
System Treatment Modules [0180] element (100) Flow to Process
Treatment "Entrained-Flow Gasifier" Equipment [0181] element (101)
7.5 H.P. Venturi Injector Pumps (#316 Stainless Steel Construction)
[0182] element (102) (4) VIP.TM. Hi-Intensity "Ionized Oxygen"
Generators [0183] element (103) (4) Venturi Injectors--All 1''
Thread Connections [0184] element (104) 1'' Dia. Stainless Steel
(Each Venturi) Return Piping
[0185] The generation of negatively electrostatically enhanced
water species may involve the use of singlet oxygen. This species
of ionized oxygen may be referred to in academic and published
literature as the superoxide ion. Superoxide vapor ions perhaps may
be employed since they may be capable of strong oxidation or
reduction reactions. In embodiments, the superoxide ion may be
produced in conjunction with a solid carbonaceous materials
gasifier system perhaps to generate negatively electrostatically
enhanced water species, for example perhaps by combining a singlet
oxygen species with water and generating long-chain negatively
charged oxygen species, hydroxide, hydrogen peroxide, peroxyl, or
the like. Moreover, such use of singlet oxygen may produce multiple
beneficial processing effects. For example, negatively
electrostatically enhanced water species produced from such singlet
oxygen may be utilized in carbonaceous reformation, as perhaps in
thermal conversion, steam reformation, devolatilization and the
like, perhaps within one or more reformation coils of a multiple
coil carbonaceous reformation vessel. Further examples may include
the release of negatively electrostatically enhanced water species,
perhaps HO.sub.2.sup.- peroxyl scavenger and highly reactive steam
vapor ions, within and throughout a multiple coil carbonaceous
reformation vessel in certain embodiments.
[0186] Table 2 illustrates what may be representative of some of
the major chemical reaction sequences whereby various negative
electrostatic enhancement species, perhaps for use in generating a
negatively electrostatically enhanced water species and perhaps
including singlet molecular oxygen ions, may be formed. Of course
these are merely illustrative of such chemical reaction sequences
and should not be construed to limit the inventive technology
thereby. Table 2 may show a reaction of atmospheric oxygen, under
the influence of short-wavelength ultraviolet energy ("UV") and a
magnetic field (referenced by the symbols "MAG. E") as it may form
a polarized or magnetic oxygen molecule, and thence may dissociate
into singlet molecular oxygen ion species (also known as Superoxide
Ions), which may be highly reactive. Table 2 also may show the
formation of ozone, which in itself may be extremely reactive, and
which also may dissociate to form singlet molecular oxygen ions.
Table 2 also may show that the singlet molecular oxygen gas may
further react with water vapor and may form hydrogen peroxide and
perhaps hydroxide radicals. As illustrated by Table 2, the ionized
oxygen may also react to form various combinations of hydrogen
peroxide and/or hydroxide in water.
TABLE-US-00002 TABLE 2 ##STR00002## ##STR00003## ##STR00004## NOTE:
EXCESS SINGLET & CHAINED SINGLET OXYGEN IONS REMAIN SATURATED
IN H.sub.2O, PROVIDING A RESIDUAL OF OXIDIZING & COAGULATIVE
REACTION AGENTS. VIP.TM. = Vapor Ion Plasma
[0187] Various embodiments may involve producing a flue gas within
a solid carbonaceous materials gasifier system, for example perhaps
within a flue gas generation zone of the gasifier system. Such a
flue gas generation zone may include for example a gasifier system
process enclosure, perhaps as wherein a combustive burner may
produce flue gas and may be enclosed within a combustive heat
enclosure to heat part of a gasifier process flow path. Moreover,
such produced flue gas in embodiments may be recycled to other
areas of the gasifier system, perhaps such as to a pretreatment
area, a pyrolysis chamber, a multiple coil carbonaceous reformation
vessel, a preliminary reformation coil of a multiple coil
carbonaceous reformation vessel, a secondary reformation coil of a
carbonaceous reformation vessel, a tertiary reformation coil of a
carbonaceous reformation vessel, or the like. Such recycling may
involve routing recycled flue gas via a flue gas recycle path
appended to the flue gas generation zone, perhaps to a flue gas
recycle input of a gasifier process flow path, wherein the recycled
flue gas perhaps may be injected into the gasifier process flow
path as with a flue gas injector.
[0188] Recycled flue gas of course may be used in any appropriate
manner consistent with the principles described herein, such as
perhaps to affect a process determinative parameter of the gasifier
system. For example, affecting a process determinative parameter
may include raising a temperature, wherein a flue gas injector may
be configured as a heater. Affecting a process determinative
parameter also may include maintaining or raising a pressure, in
which a flue gas injector may be configured as a pressure system.
Affecting a process determinative parameter further may include
chemically reacting a flue gas or temporally accelerating a
chemical reaction sequence with a flue gas, in which a flue gas
injector may be configured as a chemical reactant injector or
perhaps even a catalyst injector as appropriate. Affecting a
process determinative parameter also may include displacing oxygen
content or water content from a feedstock solids carbonaceous
material, in which a flue gas injector may be configured as an
oxygen displacement system or a water displacement system,
respectively. Affecting a process determinative parameter also may
involve affirmatively establishing a stoichiometrically
objectivistic chemic environment and stoichiometrically controlling
carbon content, in which a flue gas injector may be configured as a
stoichiometrically objectivistic carbon compensator. Moreover,
pressurizing a flue gas may be for example perhaps to at least 80
psi, and preheating a flue gas may be for example to at least
125.degree. F., at least 135.degree. F., at least 300.degree. F.,
at least 600.degree. F., or even at least 1,640.degree. F.
[0189] Various embodiments may involve selectively adjusting a
process flow rate through a gasifier process flow path, for example
perhaps with a selectively adjustable flow rate regulator.
Adjusting such a process flow rate for example may include
adjusting the flow characteristics of carbonaceous materials
entrained in the gasifier process flow path. One example in various
embodiments may involve regulating a pressure to velocity ratio for
a process flow through a multiple coil carbonaceous reformation
vessel, such as maintaining a pressure of at least 80 psi,
maintaining a flow rate of at least 5,000 feet per minute, or
perhaps maintaining a Reynolds Number value of at least 20,000.
Another example in various embodiments may involve dominatively
pyrolytically decomposing a feedstock solids carbonaceous material
and acceleratedly carbonaceously reforming the dominatively
pyrolytically decomposed feedstock solids carbonaceous material,
for example as wherein the feedstock solid carbonaceous material
may be retained within a pyrolysis chamber for greater than about 4
minutes, and wherein the pyrolytically decomposed carbonaceous
material may be carbonaceously reformed from about 4 seconds to
about 10 seconds.
[0190] In some embodiments, selectively adjusting a process flow
rate may be accomplished with a venturi injector, perhaps to
regulate a process flow rate. A venturi injector perhaps may
regulate a process flow by utilizing Bernoulli effects achieved
through a tube of varied constriction, perhaps configured in the
form of a venturi. In some embodiments, a venturi injector (17)
(FIGS. 1; 2; 8; 9; 14) may provide a cavitation or other high-mix
turbulence unit, perhaps point source, that may contribute to
increasing higher efficiency steam reformation contact, perhaps
with pass-through carbon particulate material. The venturi injector
design (17) (FIGS. 1; 2) illustrated in FIG. 8; 9 may include an
input, perhaps a steam input, a negatively electrostatically
enhanced water species input, or a select product gas input, such
as at an injection port (51) (FIGS. 1; 2), whereby complete
rotational flow turbulent mixing of an input substance may be
provided. For example, reformation coil reaction rates, perhaps as
in a multiple coil carbonaceous reformation vessel, may be
accelerated with the reactants mixing or cavitationally impinging
upon one another. Substantial mixing, including perhaps greater
than 90% mix-atomization turbulence and perhaps even near 100%
mix-atomization turbulence, perhaps may also occur in the process
flow passing through the venturi injector throat body. Also, the
exit port body of the venturi injector perhaps may be fitted with a
stop-block ring, which may create an additional zone of intense and
secondary turbulence, perhaps by impeding the process flow.
[0191] An injection port (51) may be disposed on a venturi injector
(17) in any suitable configuration, for example perhaps
tangentially positioned at the throat of the venturi injector (17).
Moreover, an injection port (51) of course may be configured to
inject any suitable substance into the venturi injector (17), and
of course consequently venturi inject the substance into a gasifier
process flow path, consistent with the principles described herein.
For example, an injection port (51) in various embodiments may
include a flue gas injection port, a pressurized flue gas injection
port, a preheated flue gas injection port, a recycled flue gas
injection port, a water injection port, a preheated water injection
port, a recycled water injection port, a negatively
electrostatically enhanced water species injection port, a
preheated negatively electrostatically enhanced water species
injection port, a recycled negatively electrostatically enhanced
water species injection port, a steam injection port, a recycled
steam injection port, a negatively electrostatically enhanced steam
injection port, a recycled negatively electrostatically enhanced
steam injection port, a select product gas injection port, a wet
select product gas injection port, a dry select product gas
injection port, and a recycled select product gas injection
port.
[0192] Utilization of a venturi injector (17) (FIGS. 1; 2; 8; 9;
14) may be provided at any suitable location or locations of a
gasifier process flow path to regulate flow rates or
characteristics, perhaps such as shown for some embodiments in
FIGS. 2; 8; 9; 14. These may be connected with one unit per each of
the reformation coils of a multiple coil carbonaceous reformation
vessel, as perhaps may be installed in a downward process flow side
of each reformation coil, or in other gasifier process flow path
control locations. Alternate venturi injector positions perhaps may
be provided as additional dynamically adjustable process
determinative parameters. The position of the venturi injectors may
be altered to provide additional high levels of process flow
efficiencies, such as perhaps when venturi injectors (17) may be
connected one each on the outlet side of each of the cyclones (20)
(FIG. 1; 2; 14). The dynamically adjustable process determinative
parameters that may define the specific, and perhaps optimal,
number of venturi injectors (17), and that may be installed within
the overall length of a reformation coil-cyclone closed process
loop, may also be a function of identifying the available energy
and carbon content of the input feedstock solids carbonaceous
material. In some embodiments, for example, it may be that no more
than four venturi injectors (17) may need to be installed, perhaps
because total pressure drop, or head losses, may increase
proportionally. A reformation coil near minimum pressure of 80 psi
to 100 psi, along with a high velocity operating throughput process
flow, of perhaps a minimum velocity of about 5,000 feet per minute
through the entire reformation coil-cyclone assembly, perhaps may
need to be maintained, as the pressure to velocity ratio may
represent an operational control variable in some embodiments. The
exact configuration and number of installed venturi injectors (17)
perhaps may be determined accordingly, so that the reformation coil
pressure and process flow velocities perhaps may be constantly
maintained at a desired level.
[0193] In some embodiments, a venturi injector (17) may include an
injection port, through which the provision of side-stream
negatively electrostatically enhanced water species injection, such
as perhaps hydrogen peroxide saturated water, may induce an excited
steam state reaction activity perhaps throughout the length of the
reformation coils of a multiple coil carbonaceous reformation
vessel. It perhaps may also thereby accelerate carbon dioxide
destruction reactions and perhaps may even substantially increase
carbon monoxide and hydrogen generation. This may be understood by
the following reaction equation sequence, Table 3:
TABLE-US-00003 TABLE 3 ##STR00005##
The scientific basis for this CO.sub.2 depletion, as may occur
within the gasifier process flow routed through the reformation
coils of a multiple coil carbonaceous reformation vessel, may be
contingent upon the generation of singlet molecular oxygen
(O.sub.2.sup.-), such as might be produced for combination with
water to produce a negatively electrostatically enhanced water
species, such as hydrogen peroxide saturated water. This may be as
shown in Table 3. When singlet oxygen, perhaps peroxide saturated
water, may be injected into the reformation coils (19) (FIGS. 1; 2;
3; 4; 14) of a multiple coil carbonaceous reformation vessel, it
may convert to a released and perhaps excited state HO.sub.2.sup.-
peroxyl ion, which may react with the gasifier process flow stream.
Embodiments may similarly produce a HO.sub.2.sup.- vapor ion, and
this may be similarly injected into the reformation process.
[0194] In certain embodiments, flow through three or four connected
venturi injectors (17) (FIGS. 1; 2; 8; 9; 14) may range at a
pressure from between about 80 psi to about 100 psi, and the
pressure may be maintained throughout areas such as the reformation
coils of a multiple coil carbonaceous reformation vessel (19)
(FIGS. 1; 2; 3; 4; 14), perhaps through associated connected
cyclones such as cyclones (20), (22), and (23) respectively (FIGS.
1; 2; 3; 4; 14). In embodiments, this pressure may perhaps overcome
the total accumulated back-pressure or the sum of the head losses
within a multiple coil carbonaceous reformation vessel, or perhaps
be able to sustain higher and perhaps optimum gasifier process
velocities such as not less than about 5,000 feet per minute
throughout the vessel. Perhaps even at, or above, an appropriate
velocity, high energy Reynolds Numbers of 20,000+ may be achieved
to perhaps ensure that tars, phenols, hydrocarbons and other debris
inorganics or particulates may not plate-out or begin to
agglomerate within the reformation coil components. Carbonaceous
materials, perhaps particulates or atomized char organic particles,
may also thoroughly react in the gasifier process flow, as perhaps
with high pressure steam generated such as within the reformation
coils, perhaps with water carry-through or perhaps a negatively
electrostatically enhanced water species being the source for the
steam. Embodiments may also produce highly efficient carbon shift
and conversion reactions. In embodiments, total reformation time
within a multiple coil carbonaceous reformation vessel, perhaps
including cyclone retention times, may be engineered to be process
maintained, perhaps even in the 4 second to 10 second range, and
perhaps as dependent upon the daily tonnage of raw feedstock solids
carbonaceous materials throughput that may be desired. Computerized
automation, perhaps coupled with continuous read mass spectrometer
and gas chromatograph online instrumentation, may be included to
provide control functions that may readily determine dynamic
adjustments to perhaps optimize process determinative parameters,
perhaps such as process flow velocities, process flow pressures,
and/or perhaps Reynolds Number operational set-points. This control
procedure perhaps may ensure that clean select product gas, perhaps
with minimal CO.sub.2 and hydrocarbon residual contamination, may
be produced at high BTU energy value. Controlled molar ratios of
select product gas components, for example such as at least 1:1
molar ratios of carbon monoxide to hydrogen and perhaps up to
approximately 20:1 molar ratios of carbon monoxide to hydrogen, may
be produced in the select product gas and perhaps may be
consistently held, perhaps with fractional or even no substantial
carbon dioxide content, nitrogen oxide content, or sulfur oxide
content contaminants present in the generated select product
gas.
[0195] Using the principles described herein, embodiments may
involve creating a high energy content select product gas. For
example, creating such a high energy content select product gas may
involve increasing its BTU value. Processing steps tending to
increase BTU value may be employed, perhaps in a manner to create a
higher BTU value select product gas as compared to processing steps
using conventional gasification techniques. Accordingly,
embodiments may involve the production of a select product gas
having a BTU value of at least 250 BTU per standard cubic foot,
having a BTU value from about 250 BTU per standard cubic foot to
about 750 BTU per standard cubic foot, having a BTU value from
about 350 BTU per standard cubic foot to about 750 BTU per standard
cubic foot, having a BTU value from about 450 BTU per standard
cubic foot to about 750 BTU per standard cubic foot, having a BTU
value from about 550 BTU per standard cubic foot to about 750 BTU
per standard cubic foot, and having a BTU value from about 650 BTU
per standard cubic foot to about 750 BTU per standard cubic foot.
In various embodiments, varied inputs of feedstock solids
carbonaceous materials may nevertheless result in consistent BTU
values for produced select product gas, with perhaps the amount of
produced select product gas varying in quantity proportion to the
BTU value of the input feedstock carbonaceous material.
[0196] Moreover, creating a high energy content select product gas
may involve increasing the purity of a select product gas. Again,
processing steps tending to increase purity may be employed,
perhaps in a manner to increase purity as compared to processing
steps using conventional gasification techniques. Purifying a
select product gas may involve, for example, isolating or perhaps
removing one or more contaminants. For example, purifying a select
product gas in various embodiments may involve minimizing nitrogen
oxide content of a select product gas, minimizing silicon oxide
content of a select product gas, minimizing carbon dioxide content
of a select product gas, minimizing sulfur content of a select
product gas, minimizing organic vapor content of a select product
gas, and minimizing metal content of a select product gas.
[0197] The processing steps used to create a high energy content
select product gas may be as have been described herein, and for
example may include but may not be limited to processing with a
negatively electrostatically enhanced water species, processing
with a recycled select product gas, processing with negatively
electrostatically enhanced steam, processing with a flue gas,
varying a process retention time, processing in at least a
preliminary reformation coil and a secondary reformation coil,
recycling an incompletely pyrolytically decomposed carbonaceous
material, and recycling an incompletely reformed carbonaceous
material.
[0198] Also using the principles described herein, embodiments may
involve predetermining a desired select product gas for output.
Such predetermining may involve consistently outputting a desired
predetermined select product gas from varied input feedstock solids
carbonaceous materials, as perhaps wherein one or more processing
stages within a solid carbonaceous materials gasifier system may
compensate for variations among input feedstock solids carbonaceous
materials. For example, predetermining in various embodiments may
involve affirmatively establishing a stoichiometrically
objectivistic chemic environment, stoichiometrically controlling
carbon content, dynamically adjusting at least one process
determinative parameter within a solid carbonaceous materials
gasifier system, or the like. Such adjustments perhaps may confer a
high degree of control over the characteristics of a predetermined
select product gas. For example, a predetermined select product gas
in various embodiments may include a variable carbon monoxide
content select product gas, a primarily carbon monoxide select
product gas, a variable hydrogen content select product gas, a
primarily hydrogen gas select product gas, a variable methane
content select product gas, a primarily methane select product gas,
a select product gas of primarily carbon monoxide and hydrogen gas
and methane, a controlled molar ratio select product gas, a
controlled molar ratio select product gas having a hydrogen gas to
carbon monoxide molar ratio of from 1:1 up to 20:1 by volume, a
controlled molar ratio select product gas having a hydrogen gas to
carbon monoxide molar ratio of at least about 1:1, a controlled
molar ratio select product gas having a hydrogen gas to carbon
monoxide molar ratio of at least about 2:1, a controlled molar
ratio select product gas having a hydrogen gas to carbon monoxide
molar ratio of at least about 3:1, a controlled molar ratio select
product gas having a hydrogen gas to carbon monoxide molar ratio of
at least about 5:1, a controlled molar ratio select product gas
having a hydrogen gas to carbon monoxide molar ratio of at least
about 10:1, a controlled molar ratio select product gas having a
hydrogen gas to carbon monoxide molar ratio from at least about 1:1
to about 20:1, a controlled molar ratio select product gas having a
hydrogen gas to carbon monoxide molar ratio from at least about 2:1
to about 20:1, a controlled molar ratio select product gas having a
hydrogen gas to carbon monoxide molar ratio from at least about 3:1
to about 20:1, a controlled molar ratio select product gas having a
hydrogen gas to carbon monoxide molar ratio from at least about 5:1
to about 20:1, a controlled molar ratio select product gas having a
hydrogen gas to carbon monoxide molar ratio from at least about
10:1 to about 20:1, a producer gas, and a synthesis gas. Moreover,
a select product gas in various embodiments may include a base
stock, as wherein the produced select product gas may be used as a
basis for post-gasifier system applications, for example as stock
for the production of additional substances. Accordingly, a select
product gas in various embodiments perhaps may include a variable
chemistry base stock, a liquid fuel base stock, a methanol base
stock, an ethanol base stock, a refinery diesel base stock, a
biodiesel base stock, a dimethyl-ether base stock, a mixed alcohols
base stock, an electric power generation base stock, or a natural
gas equivalent energy value base stock.
[0199] Further using the principles described herein, embodiments
may involve producing a high yield select product gas, perhaps even
exceeding a typical yield of conventional gasification processes
for produced select product gas from a given input feedstock solids
carbonaceous material. For example, such high yields may involve
converting greater than about 95% of the feedstock mass of a
feedstock solids carbonaceous material to select product gas,
converting greater than about 97% of the feedstock mass of a
feedstock solids carbonaceous material to select product gas,
converting greater than about 98% of the feedstock mass of a
feedstock solids carbonaceous material to select product gas,
outputting at least about 30,000 standard cubic feet of select
product gas per ton of feedstock solids carbonaceous material, or
perhaps achieving a carbon conversion efficiency of between 75% and
95% of carbon content in a feedstock solids carbonaceous material
converted to select product gas. Moreover, a high yield in certain
embodiments may involve substantially exhausting a carbon content
of an input feedstock solids carbonaceous material.
[0200] In some embodiments, the inventive technology described
herein perhaps may be configured in a modular and compact form,
perhaps that may provide an autonomous and uncomplicated select
product gas generation technology that may allow for selected
conditions operational capability and that may produce a very high
purity and high energy select product gas from a variety of input
feedstock solids carbonaceous materials, perhaps even virtually any
type of organic biomass, coal input or other carbonaceous raw
material. Of course, such modularity merely may be one aspect of
the inventive technology, and should not be construed to limit the
inventive technology only to modular embodiments. Predetermined
adjustments in operating process retention times, gas velocity
pressures, negatively electrostatically enhanced water species
injection control rates, recycled select product gas injection
parameters, and flue gas injection parameters may be included to
further provide for the generated select product gas final output
chemistry to be tuned, for example perhaps as may be related to
producing large, perhaps uncontaminated volumes of secondary
off-take commodities, such as liquid fuels, electricity generation,
hydrogen gas, and the like. Set-point operational parameters may be
included, such as progressive control of devolatilization
temperature, adjustable gas velocity and reaction time, variable
water, perhaps steam, negative electrostatic enhancement chemistry
additions, or basic steam reformation operational energy balance
capabilities. Environmental beyond-compliance discharge or perhaps
even zero discharge may be maintained in some embodiments, perhaps
with exhaust flue gases being internally recycled. In embodiments,
a negatively electrostatically enhanced water species treatment
system may be included to provide the possibility for a high
percentage, or perhaps even 100%, recycle and reuse of highly
purified water to be constantly returned back into the process. In
embodiments, small volumes of process residual or system drain
excess water may be relatively pure and perhaps may be flash
evaporated with application of system excess heat, with perhaps no
discharge to the environment. Further, applied negatively
electrostatically enhanced water processes may be included perhaps
to scrub and purify flue gas exhaust trace releases, including if
and when applicable to meet relevant air quality emission control
regulations. Embodiments even may provide one overall low
maintenance and simple operation system design that may be
economically feasible for a variety of given applications.
[0201] Some embodiments perhaps may provide an entrained flow
select product gas generation system. In some embodiments, process
parameters may allow many available and various kinds of
carbonaceous wastes or commercial feedstock materials, such as wood
waste, garbage, sewage solids, manure, agricultural or other
environmental biomass, shredded rubber tires, coal, and the like,
perhaps all to be processed perhaps through one basic platform
design. In embodiments, energy may be released and recovered as a
produced select product gas, perhaps containing high combustion
ratios of adjustable content CO and H.sub.2, perhaps along with
secondary by-product generation of water, carbon dioxide, and light
hydrocarbons that perhaps may be laced with volatile, but perhaps
condensable, organic and inorganic additional, perhaps contaminant,
compounds. Impurities perhaps may be removed within a secondary
negative electrostatically enhanced water species scrubber section
as well.
[0202] As an alternate to using coal as a commercially available
feedstock material (e.g., a feedstock perhaps with consistent
carbon conversion content), there may be a variety of non-coal
biomass resources available, perhaps being widely and
demographically dispersed. These may vary greatly in their
heterogeneous chemical characteristics makeup. Embodiments of the
inventive technology may provide a system application for an
adjustable broad spectrum, perhaps even near universal select
product gas generation process control design, and may further
provide a perhaps operational, perhaps economic, perhaps efficient
system that perhaps may be completely capable of processing nearly
any type of input carbonaceous feedstock and generating high energy
select product gas output. Embodiments of the inventive technology
also may be capable of availability throughout the world
marketplace, and may provide alternative select product gas
availability to the world marketplace.
[0203] FIGS. 18 through 22 show a portable or "pod" embodiment of
the invention. As can be understood from the FIG. 18, this
embodiment may include a pod or isolated reactor unit (211). This
isolated reactor unit (211) may be surrounded by a refractory area
(212). The refractory area (212) may include a sealed refractory
shroud (213). A feed (214) may provide material to the isolated
reactor unit (211) as shown. The material may then be acted upon in
an upper pyrolysis deck (215) and perhaps subsequently a lower
steam reformation deck (220). Each of these decks may actually be
rotating carousel decks (216). These rotating carousel decks (216),
may be aligned with a carousel drive shaft (217), which may be
supported by an upper bearing support (218) and perhaps a bottom
oil seal pivot bearing (219). The entire isolated reactor unit
(211) may be surrounded at least partially by a flue gas chamber
(221). For reasons discussed earlier, ionized water nozzles or
injectors (222) may be included as well. Spend material may fall
into an ash drop (223), which may pass through an air lock valve
(224), an ash auger (226), and ultimately into an ash collection
bin (227). The system may be driven by a gearbox drive (225).
[0204] To provide the input feed, and embodiment may include a feed
section (229). The feed section (229) may provide material from a
bunker pin or the like. Perhaps through multiple venturi injectors
(228) that each permit an adequate amount of pressure increase. The
feed section (229) may be surrounded by a gas shroud chamber (230).
This gas shroud chamber (230), allows passage of flue or product
gas, which may permit pre-heating a feedstock material. As shown,
material may pass into a feed plenum (231), which may act as a
separator (232) to separate a motive agent such as a gas or the
like from the feed material. The feed plenum (231), may have an
access (233) through which a motive agent or the like may pass in
or out. As may be understood, in an instance where the motive agent
is an agent such as flue gas, the excess gas may pass out of the
access (233) and return to the system for recycling or reuse.
Similarly, the system may include a shroud flue gas output (235),
which may permit flue gas output shroud gas for return to the
system or the like. This return may have various input locations,
such as the venturi injectors or other locations.
[0205] Further, the "pod" embodiment shown may include a raw
feedstock input (237) such as from a feedstock bin or the like.
This feedstock input (237) can accept an external source of
material for appropriate processing.
[0206] FIG. 21 shows a similar system in a more generic
understanding. As one way providing compact processing, operations
may include mechanically propelling at least one carbonaceous
materials pyrolysis decomposition platform. This carbonaceous
materials pyrolysis decomposition platform such as the upper
pyrolysis deck (215). Operations may also include mechanically
propelling at least one pyrolytically decomposed carbonaceous
materials processor platform such as the lower steam reformation
deck (220). These may be propelled by a mechanical gasifier drive
system (201). In fact both the decks may be platforms and thus the
system may include a mechanically propelled carbonaceous materials
pyrolysis decomposition platform (202) and a mechanically propelled
pyrolytically decomposed carbonaceous materials processor platform
(203). In this fashion the system can be considered as having a
plurality of environment differentiated mechanically propelled
pyrolytically decomposed carbonaceous materials processor
platforms.
[0207] It should be understood that the type of mechanical
propulsion used can vary. In one embodiment, the system may include
rotating platforms. As shown, there may be a rotating pyrolytically
decomposed carbonaceous materials processor platform such as the
upper pyrolysis deck (215), and a rotating a carbonaceous materials
pyrolysis decomposition platform, such as the lower steam
reformation deck (220). As may be understood, it may be
advantageous for embodiments to have the rotations be horizontal
rotations, that is, in a perpendicular to gravity. In addition, it
may be advantageous to coordinate the rotation are other movements
involved. In this way, the system may involve coordinated movement
platforms or coordinatively mechanically propelling items for
appropriate processing. These coordinated movements may be
synchronous and may even be driven by a single drive. Thus, the
system may include synchronous duality of movement platforms,
driven by a single mechanical gasifier drive system. As can be
appreciated, by singularly driving both platforms, only one drive
system may be necessary. In addition, the platforms may rotate at
identical rates for one type of coordinated processing.
[0208] Processed material may be subjected to different
environments as it sequences through the reactor. These
environments may be differentiated by any number of variables. As
but some examples, the environments may be differentiated by
process factor variable such as: a process material size factor, a
process temperature factor, a process duration factor, a
differentiated environment factor, a reactor electrostatic steam
factor, a chemic environment factor, a water environment factor, a
negative electrostatic charge water environment factor, a
differentiated carbon content factor, a differentiated oxygen
content factor, a differentiated flue gas content factor, a
differentiated product gas factor, a recycled process material
factor, among others. The platforms and even the generic processor
can sequence and have different components as well. Processors may
be: a variable temperature zone carbonaceous feedstock processor, a
carbonaceous feedstock processor configured to establish a
temperature from 125 degrees Fahrenheit to 135 degrees Fahrenheit,
a carbonaceous feedstock processor configured to establish a
temperature from 135 degrees Fahrenheit to 300 degrees Fahrenheit,
a carbonaceous feedstock processor configured to establish a
temperature from 300 degrees Fahrenheit to 1,000 degrees
Fahrenheit, a carbonaceous feedstock processor configured to
establish a temperature from 1,000 degrees Fahrenheit to 1,640
degrees Fahrenheit, and a carbonaceous feedstock processor
configured to establish a temperature from 1,640 degrees Fahrenheit
to 1,850 degrees Fahrenheit.
[0209] In one embodiment, the invention may include carousel
platforms that may even simply rotate about a horizontal axis.
Thus, the system may involve mechanically propelling a carbonaceous
materials pyrolysis carousel, and even mechanically propelling a
pyrolytically decomposed carbonaceous materials processor carousel.
By configuring the carousels or carousel platforms at different
levels, the system may include a tiered carousel (204). That tiered
carousel (204), may involve carousel tiered platforms as shown. It
may also involve coaxial and perhaps even vertical tiering. Thus
there may be a coaxial carousel tiered drive system that acts to
mechanically propel a tiered carousel and shown.
[0210] An important part of sequentially processing material can
include transferring the material between different environments.
This can occur through a process transfer that moves processed
material between different environments. In the embodiment shown,
this process transfer can include one or more fixed decomposed
carbonaceous materials scrapers (206), as well as one or more
dispersionary freefall transfers (205). By the dispersionary
freefall transfer (205) material may gravimetrically fall from one
level to the next. This can promote mixing and more complete
processing. Thus, as carousel platforms rotate, the material on the
platforms may be subjected to fixed element scraping, which can
push the material off of the platform and cause it to fall onto the
next processing platform.
[0211] In each of the reactor sections, it should be understood
that additional platforms can be provided. For example, there can
be a plurality of interstitial output coordinated platforms. More
than one platform can be used in the pyrolysis processes such as so
that the material is adequately decomposed or the like. Both the
pyrolysis and reformation functions can have multiple platforms.
For instance, as shown it can be understood that the system may
include first and second pyrolysis environment process platforms,
as well as first and second carbonaceous reformation environment
process platforms. Each of these may include differentiated status
such as differentiated pyrolytically decomposing, as well as
differentiated reformation steps.
[0212] As can be understood from the figures, the "pod" concept can
permit many advantages. As shown in FIGS. 18 and 21 and discussed
later, systems may be portable. In addition, environmental safety
can be promoted by entirely encasing aspects of the system. Thus,
by substantially sealingly wholly containing the reactor or the
like, a more safe system can be provided. As shown, the sealed
refractory shroud (213) may be configured to circumscribe and
create a substantially sealed process chamber and a sealed burner
chamber (241). Thus there can be a substantially wholly contained
gasifier. This encasement may have thermal advantages and may be a
substantially sealed circumscribing heat shield encasement that
thermally encases aspects of the system. The sealed refractory
shroud (213) and other components may create a thermal
circumscribing heat shield encasement. This may surround the
chamber, the platforms, the reactors, and the like. Operations
performs may even include: sealably encased mechanically
propelling, sealably encased pyrolytically decomposing, sealably
encased carbonaceous reforming, encased processing, encased
generating, encased recycling, and even generating a flue gas
within an encased gasifier system, as but a few.
[0213] FIG. 22 shows a lower portion of a "pod" embodiment of the
present invention. This may include a product synthesis gas
combustion bottom burner (241) so that he increasing temperature is
provided at a bottom location. This may aid in effecting a tiered
heat distribution, where there is increasing temperature at lower
levels. This can work in conjunction with the fact that processed
material sequentially falls from one carousel to another and thus
is sequentially treated to increasing temperatures.
[0214] In encased designs such as the "pod" system shown, the
substantially sealed circumscribing heat shield encasement may have
a variety of inputs and outputs (242). Among others, these may
include a recirculatory water input (243) and a recirculatory water
output (244) such as from and external, unencased, or perhaps even
separate treatment system that operates for treating water, gas,
material or the like. These systems may even be recirculatory and
thus the system may operate for inputting recirculatory water and
outputting recirculatory water from an encased environment. The
outputs can be varied and may include: a negatively
electrostatically enhanced water species processed select product
gas output, a flue gas processed select product gas output, a
varied retention time processed select product gas output, a select
product gas processed in at least a preliminary reformation coil
and a secondary reformation coil output, a select product gas
processed with a recycled incompletely pyrolytically decomposed
carbonaceous material output, and a select product gas processed
with a recycled incompletely reformed carbonaceous material output,
among others.
[0215] The input can also have ferried configurations. As shown,
one type of input can include a pneumatic propellant system (245).
This could use flue gas and be a flue gas propellant system,
synthesis gas and be a product synthesis gas propellant system. As
such either flue gas or synthesis gas might be used for propelling
materials such as feedstock solids into the reactor environments.
Thus the system may have a pneumatically propelled feedstock solids
carbonaceous material input that may even pneumatically propel
solids up into an areas such as the feed plenum. By pneumatically
propelling the feedstock, the input may act as a dispersionary
feedstock solids carbonaceous material input (237) that disperses a
feedstock. It may also subject it to a gas, such as for oxygen
depletion, pre-heating, or the like.
[0216] As shown by running the materials up an incline, the system
may include an accretive feedstock energy system (245) through
which the system may operate for feedstock energy accretively
propelling of the feedstock. Thus the feedstock has higher energy
(potential or kinetic) after input. This system may also be an
accretive feedstock potential energy input system (248) that causes
an increase in the potential energy so that the feedstock can fall
down from one platform to another by gravity without needing
additional energy or drive mechanisms. The embodiment shown
involves an inclined feedstock solids carbonaceous material input
(249) that drives the feedstock solids carbonaceous material up an
incline. This incline may even be vertical if desired such as for
space saving reasons or the like.
[0217] In the embodiment shown, the input is shown as a coaxial
feed system (250). This type of the system can operate for
coaxially feeding and coaxially propelling a feedstock in one path
and something else in a perhaps surrounding path. In one embodiment
in this may involve outer coaxially feeding a flue gas and inner
coaxially feeding a feedstock solids. These may even be established
in opposite coaxial flows so that one flows up and the other down,
or one flows left and the other right. As shown there may be an
inner feedstock pathway and an outer flue gas pathway. These two
opposite flow direction pathways may serve to put feedstock in and
to exit flue gas or the like. While at the same time pre-heating
the material and providing a feedstock coaxial pre-heater system
(250) that may precondition it for ultimate processing. In order to
permit the pressure differential required from a feedstock, due to
the higher pressure processing reactor, the system may include one
or more continuous feed, pressure differential venturi
injectors.
[0218] As mentioned earlier, it may be advantageous to utilize
water, and perhaps even negative electrostatically enhanced water
for processing. This may be through use of a recirculatory
negatively electrostatically enhanced water species treatment
system (259). There may be one or more negatively electrostatically
enhanced water species injectors perhaps positioned adjacent at
least one of the platforms so that the water or steam can appear in
the process at the desired location. These injectors may even be
sidewall negative electrostatically enhanced water species
injectors (253) that are positioned along the sidewall such as that
one carousel location. This sidewall may be an inner or outer
sidewall. There may even be one or more driveshaft negative
electrostatically enhanced water species injectors (254) that act
to disburse water or steam from in the vicinity of the driveshaft.
This can aid in providing steam at the inner and outer locations of
the carousel environment. As shown in FIG. 11, the entire water
treatment process can be accomplished external to the encased area.
There may even be at a trailer adjacent recirculatory negatively
electrostatically enhanced water species treatment system (259)
that would transport FIG. 11 water treatment system. It should be
understood that although this is shown as attached on one trailer,
such a system can be entirely separate and perhaps even on a
separate trailer or otherwise. As such an embodiment could present
a separately portable recirculatory negatively electrostatically
enhanced water species treatment system. There could also be an
adjacent treatment system such as shown in FIG. 19 where the water
treatment components are adjacent the processor and may be on one
or either side.
[0219] As may be appreciated, it may be desirable to make a
portable or at least movable system. This could be configured such
as on a trailer base (258). In order to permit transportation of
the largest possible system, designed include a disabling collapse
element (255). Such an element could fold-down, detach, or separate
elements or components to permit transporting the entire system.
Embodiments may permit compactly transportive collapsing parts of
the system and perhaps even collectively moving a substantial
portion of the gasifier system. Once moved the collapsed portions
may be reassembled thus re-establishing the system in an operative
state. Various portions can be made collapsible. These could
include: a repositionable carbonaceous feedstock input, a
detachable carbonaceous feedstock input, a separable carbonaceous
feedstock input, a collapsible inclined carbonaceous feedstock
input, a collapsible inclined carbonaceous feedstock input, a
collapsible feed plenum, and the like. As shown, one aspect that
can facilitate as compacted design is possible, may include having
an off center feedstock solids carbonaceous material input (256).
Collapsing the system can include collapsing at least a portion of
a recirculatory water system. This may occur by repositioning at
least one water tank, by detaching at least a portion of a
recirculatory system, by separating, collapsing, or otherwise
reducing in size aspects of the water system.
[0220] Of course, it may be desirable to transport the system. This
may occur on a trailer or perhaps even on a low center section
trailer (258). Thus as shown, the processor may be positioned at
least partially in a low center section of a trailer base. The
entire system could be on one or more trailers. As shown a
particularly compact system is configured to be put entirely on a
single road transportable trailer. Thus an extremity of system on
the trailer base may be collapsed to reduce at least one operable
condition external dimension for transport. In this manner the
system may be sized from both the perspectives of providing a large
or a small system. These designs can be configured to be sized for
process rates such as: at least about 25 tons per day, at least
about 50 tons per day, at least about 100 tons per day, at least
about 150 tons per day, at least about 200 tons per day, and at
least about 250 tons per day up to about 500 tons per day.
[0221] As may be easily understood from the foregoing, the basic
concepts of the present inventive technology may be embodied in a
variety of ways. It may involve both select product gas generation
techniques as well as devices to accomplish the appropriate select
product gas generation. In this application, the select product gas
generation techniques are disclosed as part of the results shown to
be achieved by the various devices described and as steps which are
inherent to utilization. They are simply the natural result of
utilizing the devices as intended and described. In addition, while
some devices are disclosed, it should be understood that these not
only accomplish certain methods but also can be varied in a number
of ways. Importantly, as to all of the foregoing, all of these
facets should be understood to be encompassed by this
disclosure.
[0222] The discussion included in this patent application is
intended to serve as a basic description. The reader should be
aware that the specific discussion may not explicitly describe all
embodiments possible; many alternatives are implicit. It also may
not fully explain the generic nature of the invention and may not
explicitly show how each feature or element can actually be
representative of a broader function or of a great variety of
alternative or equivalent elements. Again, these are implicitly
included in this disclosure. Where the invention is described in
device-oriented terminology, each element of the device implicitly
performs a function. Apparatus claims may not only be included for
the device described, but also method or process claims may be
included to address the functions the invention and each element
performs. Neither the description nor the terminology is intended
to limit the scope of the claims that will be included in any
subsequent patent application.
[0223] It should also be understood that a variety of changes may
be made without departing from the essence of the inventive
technology. Such changes are also implicitly included in the
description. They still fall within the scope of this inventive
technology. A broad disclosure encompassing both the explicit
embodiment(s) shown, the great variety of implicit alternative
embodiments, and the broad methods or processes and the like are
encompassed by this disclosure and may be relied upon when drafting
the claims for any subsequent patent application. It should be
understood that such language changes and broader or more detailed
claiming may be accomplished at a later date (such as by any
required deadline) or in the event the applicant subsequently seeks
a patent filing based on this filing. With this understanding, the
reader should be aware that this disclosure is to be understood to
support any subsequently filed patent application that may seek
examination of as broad a base of claims as deemed within the
applicant's right and may be designed to yield a patent covering
numerous aspects of the invention both independently and as an
overall system.
[0224] Further, each of the various elements of the inventive
technology and claims may also be achieved in a variety of manners.
Additionally, when used or implied, an element is to be understood
as encompassing individual as well as plural structures that may or
may not be physically connected. This disclosure should be
understood to encompass each such variation, be it a variation of
an embodiment of any apparatus embodiment, a method or process
embodiment, or even merely a variation of any element of these.
Particularly, it should be understood that as the disclosure
relates to elements of the inventive technology, the words for each
element may be expressed by equivalent apparatus terms or method
terms--even if only the function or result is the same. Such
equivalent, broader, or even more generic terms should be
considered to be encompassed in the description of each element or
action. Such terms can be substituted where desired to make
explicit the implicitly broad coverage to which this inventive
technology is entitled. As but one example, it should be understood
that all actions may be expressed as a means for taking that action
or as an element which causes that action. Similarly, each physical
element disclosed should be understood to encompass a disclosure of
the action which that physical element facilitates. Regarding this
last aspect, as but one example, the disclosure of a "filter"
should be understood to encompass disclosure of the act of
"filtering"--whether explicitly discussed or not--and, conversely,
were there effectively disclosure of the act of "filtering", such a
disclosure should be understood to encompass disclosure of a
"filter" and even a "means for filtering". Such changes and
alternative terms are to be understood to be explicitly included in
the description.
[0225] Any patents, publications, or other references mentioned in
this application for patent are hereby incorporated by reference.
Any priority case(s) claimed by this application is hereby appended
and hereby incorporated by reference. In addition, as to each term
used it should be understood that unless its utilization in this
application is inconsistent with a broadly supporting
interpretation, common dictionary definitions should be understood
as incorporated for each term and all definitions, alternative
terms, and synonyms such as contained in the Random House Webster's
Unabridged Dictionary, second edition are hereby incorporated by
reference. Finally, all references listed in the following are
hereby appended and hereby incorporated by reference, however, as
to each of the above, to the extent that such information or
statements incorporated by reference might be considered
inconsistent with the patenting of this/these inventive technology
such statements are expressly not to be considered as made by the
applicant(s).
[0226] Thus, the applicant(s) should be understood to have support
to claim and make a statement of invention to at least: i) each of
the process devices as herein disclosed and described, ii) the
related methods disclosed and described, iii) similar, equivalent,
and even implicit variations of each of these devices and methods,
iv) those alternative designs which accomplish each of the
functions shown as are disclosed and described, v) those
alternative designs and methods which accomplish each of the
functions shown as are implicit to accomplish that which is
disclosed and described, vi) each feature, component, and step
shown as separate and independent inventions, vii) the applications
enhanced by the various systems or components disclosed, viii) the
resulting products produced by such systems or components, ix) each
system, method, and element shown or described as now applied to
any specific field or devices mentioned, x) methods and apparatuses
substantially as described hereinbefore and with reference to any
of the accompanying examples, xi) the various combinations and
permutations of each of the elements disclosed, xii) each
potentially dependent claim or concept as a dependency on each and
every one of the independent claims or concepts presented, and
xiii) all inventions described herein.
[0227] With regard to claims whether now or later presented for
examination, it should be understood that for practical reasons and
so as to avoid great expansion of the examination burden, the
applicant may at any time present only initial claims or perhaps
only initial claims with only initial dependencies. Support should
be understood to exist to the degree required under new matter
laws--including but not limited to European Patent Convention
Article 123(2) and United States Patent Law 35 USC 132 or other
such laws--to permit the addition of any of the various
dependencies or other elements presented under one independent
claim or concept as dependencies or elements under any other
independent claim or concept. In drafting any claims at any time
whether in this application or in any subsequent application, it
should also be understood that the applicant has intended to
capture as full and broad a scope of coverage as legally available.
To the extent that insubstantial substitutes are made, to the
extent that the applicant did not in fact draft any claim so as to
literally encompass any particular embodiment, and to the extent
otherwise applicable, the applicant should not be understood to
have in any way intended to or actually relinquished such coverage
as the applicant simply may not have been able to anticipate all
eventualities; one skilled in the art, should not be reasonably
expected to have drafted a claim that would have literally
encompassed such alternative embodiments.
[0228] Further, if or when used, the use of the transitional phrase
"comprising" is used to maintain the "open-end" claims herein,
according to traditional claim interpretation. Thus, unless the
context requires otherwise, it should be understood that the term
"comprise" or variations such as "comprises" or "comprising", are
intended to imply the inclusion of a stated element or step or
group of elements or steps but not the exclusion of any other
element or step or group of elements or steps. Such terms should be
interpreted in their most expansive form so as to afford the
applicant the broadest coverage legally permissible.
[0229] Finally, any claims set forth at any time are hereby
incorporated by reference as part of this description of the
inventive technology, and the applicant expressly reserves the
right to use all of or a portion of such incorporated content of
such claims as additional description to support any of or all of
the claims or any element or component thereof, and the applicant
further expressly reserves the right to move any portion of or all
of the incorporated content of such claims or any element or
component thereof from the description into the claims or
vice-versa as necessary to define the matter for which protection
is sought by this application or by any subsequent continuation,
division, or continuation-in-part application thereof, or to obtain
any benefit of, reduction in fees pursuant to, or to comply with
the patent laws, rules, or regulations of any country or treaty,
and such content incorporated by reference shall survive during the
entire pendency of this application including any subsequent
continuation, division, or continuation-in-part application thereof
or any reissue or extension thereon.
* * * * *