U.S. patent application number 13/809153 was filed with the patent office on 2013-12-05 for plasma feedwater and/or make up water energy transfer system.
The applicant listed for this patent is James Charles Juranitch, Alan C. Reynolds. Invention is credited to James Charles Juranitch, Alan C. Reynolds.
Application Number | 20130318968 13/809153 |
Document ID | / |
Family ID | 45441478 |
Filed Date | 2013-12-05 |
United States Patent
Application |
20130318968 |
Kind Code |
A1 |
Juranitch; James Charles ;
et al. |
December 5, 2013 |
Plasma Feedwater and/or Make Up Water Energy Transfer System
Abstract
A method and system for converting a feedstock using thermal
plasma or other gassifier, into a feedwater or make up water energy
transfer system. Feedstock is any organic material or fossil fuel.
The energy transferred in the feedwater or make N up water is used
in any Rankine or other steam process, or any process that requires
heat. Heat is extracted from a gas product issued by a gassifier
and is delivered to a power plant via its feedwater system or make
up water system. Preferably, the gassifier is a plasma gassifier
and the gas product is syngas that is combusted in an afterburner.
A heated air flow and/or EGR flow is provided the afterburner at a
variable flow rate that is responsive an operating characteristic
of the afterburner.
Inventors: |
Juranitch; James Charles;
(Ft. Lauderdale, FL) ; Reynolds; Alan C.; (Novi,
MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Juranitch; James Charles
Reynolds; Alan C. |
Ft. Lauderdale
Novi |
FL
MI |
US
US |
|
|
Family ID: |
45441478 |
Appl. No.: |
13/809153 |
Filed: |
July 8, 2011 |
PCT Filed: |
July 8, 2011 |
PCT NO: |
PCT/US11/01197 |
371 Date: |
July 29, 2013 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
61399294 |
Jul 8, 2010 |
|
|
|
61403929 |
Sep 23, 2010 |
|
|
|
Current U.S.
Class: |
60/645 |
Current CPC
Class: |
C10J 2300/1606 20130101;
F23G 2206/203 20130101; F23G 2900/00001 20130101; C10J 2300/0906
20130101; F23G 5/16 20130101; C10J 2300/1238 20130101; C10J
2300/165 20130101; C10J 2300/1807 20130101; F23G 2201/303 20130101;
Y02E 20/12 20130101; C10J 2300/0996 20130101; C10J 3/18 20130101;
F23G 2202/101 20130101; F23G 5/0276 20130101; F23G 5/46 20130101;
C10J 2300/0946 20130101; F23G 2207/30 20130101; C10J 2300/0989
20130101; F22D 1/003 20130101; F23G 5/50 20130101; F23G 5/085
20130101; F23G 5/033 20130101; Y02P 20/129 20151101 |
Class at
Publication: |
60/645 |
International
Class: |
F22D 1/00 20060101
F22D001/00 |
Claims
1. A method of extracting heat energy from a gassifier and
delivering the heat energy to a power plant, the method comprising
the steps of: extracting heat energy from a gas product issued by
the gassifier; and delivering the extracted heat energy to a
selectable combination of a feedwater system and a make up water
system of a power plant.
2. The method of claim 1, wherein the gassifier is a plasma
gassifier.
3. The method of claim 1, wherein the gas product is syngas.
4. The method of claim 3, wherein prior to performing said step of
extracting heat energy there is provided the further step of
combusting the syngas in an afterburner.
5. The method of claim 4, wherein there is further provided the
step of supplying an air flow to the afterburner.
6. The method of claim 5, wherein said step of supplying an air
flow to the afterburner is performed in excess of stoichiometric to
cool the outlet charge of the afterburner.
7. The method of claim 5, wherein said step of supplying air flow
to the afterburner is performed at a selectable one of an
approximately stoichiometric level and a sub-stoichiometric
level.
8. The method of claim 4, wherein there is further provided the
step of injecting recirculated exhaust gas into the
afterburner.
9. The method of claim 8, wherein said step of injecting
recirculated exhaust gas into the afterburner is performed at a
flow rate that is varied in response to an afterburner temperature
characteristic.
10. The method of claim 5, wherein said step of supplying an air
flow to the afterburner is performed at a variable flow rate.
11. The method of claim 10, wherein the flow rate is varied in
response to an A/F ratio.
12. The method of claim 10, wherein the flow rate is varied in
response to an afterburner temperature characteristic.
13. The method of claim 5, wherein there is further provided the
step of preheating the air flow to the afterburner to reclaim
energy from the system.
14. The method of claim 1, wherein the gassifier is a plasma
gassifier, and there is further provided the step of cooling a
plasma torch by using a selectable combination of an incoming
feedwater and a make up water from the power plant.
15. The method of claim 1, wherein there is provided the further
step of supplementing the extracted heat energy with a selectable
one of natural gas and propane.
16. The method of claim 1, wherein there is provided the further
step of reducing emissions by subjecting the gas product to a
ceramic media filter.
17. A method of providing heat energy from a gassifier to a power
plant, the method comprising the steps of: issuing a gas product
from the gassifier; delivering the gas product to a heat exchanger
arrangement; delivering a selectable combination of feedwater and
make up water from the power plant to the heat exchanger
arrangement; extracting heat energy from the gas product in the
heat exchanger arrangement; delivering the extracted heat energy to
the selectable combination of feedwater and make up water from the
power plant in the heat exchanger arrangement; and returning the
selectable combination of feedwater and make up water with the
extracted heat energy to the power plant.
18. The method of claim 17, wherein the gassifier is a plasma
gassifier, and the gas product is a syngas product.
19. The method of claim 18, wherein the plasma gassifier is
provided with a plasma torch, and there is provided the further
step of cooling the plasma torch with the selectable combination of
feedwater and make up water of the power plant.
20. The method of claim 18, wherein prior to performing said step
of delivering the gas product to the heat exchanger arrangement,
there is provided the further step of combusting the syngas in an
afterburner.
21. The method of claim 20, wherein there is further provided the
step of supplying an air flow to the afterburner.
22. The method of claim 21, wherein said step of supplying an air
flow to the afterburner is performed at a variable flow rate
responsive to an operating condition of the afterburner.
23. The method of claim 17, wherein there is provided the further
step of supplementing the extracted heat energy with a selectable
one of natural gas and propane.
24. The method of claim 17, wherein there is provided the further
step of injecting recirculated exhaust gas (EGR) into the
afterburner.
25. The method of claim 24, wherein said step of injecting
recirculated exhaust gas (EGR) into the afterburner is performed at
a variable flow rate responsive to an operating condition of the
afterburner.
Description
RELATIONSHIP TO OTHER APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application Ser. No. 61/399,294 filed Jul. 8, 2010; and of
U.S. Provisional Patent Application Ser. No. 61/403,929, filed Sep.
23, 2010. The disclosures of those provisional patent applications
are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally processes and systems for
generating electrical power, and more particularly, a process and
system that extracts heat energy from the output gas of a
gassifier, provides the extracted heat energy the system for
generating electrical power via its associated feedwater system or
make up water system, and can be applied any heat transfer process,
including simple steam generation.
[0004] 2. Description of the Related Art
[0005] There is significant interest in renewable energy projects.
Thermal plasma has consistently distinguished itself as a high
efficiency, low emissions gasification process for just about any
feedstock, and has been identified as one of the most desirable
processes for use in producing energy from renewable fuels.
[0006] If an analysis of plasma waste (or other renewable fuels)
relative other energy facilities is conducted, it becomes apparent
that the lack of existing plasma projects is not exclusively the
result of technological problems, but also results from the
relatively poor economics associated with this technology. Plasma
technology is not inexpensive when compared disposition of waste
using landfill, incineration, or conventional gasification.
[0007] Many plasma projects fail at the onset, notwithstanding
extensive initial marketing efforts, usually as a result of
inadequate financing and low or nonexistent profitability. Recently
some states have allocated bonuses for development and use of
renewable energy, and such efforts have stimulated the use of
plasma systems in the production of energy. Unfortunately, it is
expected that this modest boon to plasma usage will be short lived,
as it represents an artificial market that is a poor model on which
build a business. This is particularly problematical when one
considers that these facilities are expected produce power
cost-effectively for at least fifty years.
[0008] Many plasma projects in the past have pinned false hopes on
high tipping fees for hazardous waste without fully understanding
the complications that are associated with such materials. The
handling of these materials is not only complex and expensive, but
also potentially dangerous if not properly engineered. The entire
process and the facility itself thus become unduly expensive.
[0009] Most counties emphatically state that they do not desire
that large quantities of hazardous waste be transported through
their communities. However, large quantities of such waste must be
generated if the facility is achieve profitability. The production
and delivery of the hazardous waste have be carefully coordinated
since it is dangerous store biological and other hazardous waste
feedstock.
[0010] Some companies have invested unrealistic hopes in "high
value plasma by-products" such as Rockwool. This product has merit,
but the production, distribution, and sale of the product are all
in their infancy. It is an unfortunate reality that in order that a
production facility be economically viable, it must achieve
profitability beginning very early in its operation. Energy
companies cannot wait several years develop a product and a
market.
[0011] The process and system of the present invention overcomes
the economic hurdles noted above for a plasma system. It is be
understood, however, that the invention herein described is not
limited the use of a plasma gassifier. In some embodiments of the
invention, conventional gassifiers can be employed. The use of a
plasma gassifier in the practice of the present invention simply
increases overall system effectiveness.
[0012] The system of the present invention is simple, flexible, and
very energy efficient. In short, it produces a large amount of
renewable power from a feedstock such as Municipal Solid Waste
("MSW"), for a very small capital investment. Any feedstock can be
used, including, for example, biomass or algae. MSW is but a common
example of a renewable feedstock.
[0013] It is, therefore, an object of this invention provide a
simple and cost-effective renewable energy system.
[0014] It is another object of this invention provide a renewable
energy system that can consume virtually any feedstock.
[0015] It is also an object of this invention provide a simple and
cost-effective renewable energy system that can use a conventional
gassifier.
[0016] It is a further object of this invention provide a simple
and cost-effective renewable energy system that can use a plasma
gassifier.
[0017] It is additionally an object of this invention provide a
process and system for enhancing the thermal efficiency of a
Rankine or other steam process, or any process that requires
heat.
[0018] It is yet a further object of this invention provide a
process and system for enhancing the thermal efficiency of a power
plant.
[0019] It is also another object of this invention provide a
process and system for extracting heat energy from a renewable
energy system that can consume virtually any feedstock and
providing the heat energy a Rankine or other steam process, or any
process that requires heat.
[0020] It is yet an additional object of this invention provide a
process and system for extracting heat energy from a plasma
gassifier and providing the heat energy to any process that
requires heat, including a power plant.
[0021] It is yet an additional object of this invention provide a
process and system for extracting heat energy from a plasma
gassifier and providing the heat energy to any heat transfer
process, including simple steam generation.
SUMMARY OF THE INVENTION
[0022] The foregoing and other objects are achieved by this
invention which provides a method of extracting heat energy from a
gassifier and delivering the heat energy a power plant. In
accordance with a first method aspect of the invention, there are
provided the steps of extracting heat energy from a gas product
issued by the gassifier, and delivering the extracted heat energy a
selectable combination of a feedwater system and a make up water
system of a power plant.
[0023] In one embodiment of the invention, the gassifier is a
plasma gassifier, and is the gas product is syngas. In a further
embodiment, prior performing the step of extracting heat energy,
there is provided the further step of combusting the syngas in an
afterburner.
[0024] In some embodiments, there is provided the further step of
supplying an air flow the afterburner. The step of supplying the
air flow the afterburner is performed in excess of stoichiometric
cool the outlet charge of the afterburner. In one embodiment of the
invention, the step of supplying air flow the afterburner is
performed at a selectable one of an approximately stoichiometric
level and a sub-stoichiometric level. In other embodiments,
however, the step of supplying air flow the afterburner is
performed at a selectable one of an approximately stoichiometric
level and a sub-stoichiometric level.
[0025] In some embodiments, the step of supplying an air flow the
afterburner is performed at a variable flow rate. The flow rate is
varied in response an A/F ratio or an afterburner temperature
characteristic. In a specific illustrative embodiment of the
invention, there is further provided the step of preheating the air
flow the afterburner reclaim energy from the system.
[0026] In another embodiment, there is provided the step of
injecting recirculated exhaust gas (i.e., EGR) into the
afterburner. In other embodiments, the step of injecting
recirculated exhaust gas into the afterburner is performed at a
flow rate that is varied in response an afterburner temperature
characteristic. Exhaust Gas Recirculation (EGR) is used cool the
charge and thereby reduce the emissions in the afterburner. This
aspect of the invention can be combined with any of less than
stoichiometric air injection, equal stoichiometric air injection,
or greater than stoichiometric air injection.
[0027] In an advantageous embodiment of the invention, the
gassifier is a plasma gassifier, and there is further provided the
step of cooling the plasma torch of the plasma gassifier by using
an incoming feedwater and/or make up water from the power plant.
One or more of natural gas, syngas, and propane are used in some
embodiments of the invention supplement the extracted heat energy.
Additionally, a ceramic media filter is used reduce emissions.
[0028] In accordance with a further method aspect of the invention,
there is provided a method of providing heat energy from a
gassifier a power plant. The method includes the steps of:
[0029] issuing a gas product from the gassifier;
[0030] delivering the gas product a heat exchanger arrangement;
[0031] delivering feedwater and/or make up water from the power
plant the heat exchanger arrangement;
[0032] extracting heat energy from the gas product in the heat
exchanger arrangement;
[0033] delivering the extracted heat energy the feedwater and/or
make up water from the power plant in the heat exchanger
arrangement; and
[0034] returning the feedwater and/or make up water with the
extracted heat energy the power plant.
[0035] In one embodiment of this further method aspect of the
invention, the gassifier is a plasma gassifier, and the gas product
is a syngas product. In a further embodiment, the plasma gassifier
is provided with a plasma torch, and there is provided the further
step of cooling the plasma torch with the feedwater and/or make up
water of the power plant.
[0036] In a still further embodiment of the invention, prior
performing the step of delivering the gas product the heat
exchanger arrangement, there is provided the further step of
combusting the syngas in an afterburner.
[0037] In other embodiments, there is further provided the step of
supplying an air flow the afterburner. In an advantageous
embodiment, the step of supplying the air flow the afterburner is
performed at a variable flow rate that is responsive to an
operating condition of the afterburner.
[0038] In other embodiments, recirculated exhaust gas (EGR) is
injected into the afterburner. In some embodiments, the step of
injecting recirculated exhaust gas (EGR) into the afterburner is
performed at a variable flow rate responsive an operating condition
of the afterburner.
[0039] The extracted heat energy is, in some embodiments,
supplemented with a selectable one of liquid or gaseous fuels such
as natural gas or propane.
BRIEF DESCRIPTION OF THE DRAWING
[0040] Comprehension of the invention is facilitated by reading the
following detailed description, in conjunction with the annexed
drawing, in which:
[0041] FIG. 1 is a simplified schematic representation of a process
and system for generating energy from a renewable energy source
constructed in accordance with the principles of the invention;
[0042] FIG. 2 is a simplified schematic representation of a further
embodiment of the invention; and
[0043] FIG. 3 is a simplified schematic representation of a further
embodiment of the invention that includes injection of recirculated
exhaust gas (EGR) used for any heat reclamation process such as
steam or feedwater or make up water when combined with a gassifier
and more specifically a plasma gassifier and afterburner
system.
DETAILED DESCRIPTION
[0044] FIG. 1 is a simplified schematic representation of a process
and system for generating energy from a renewable energy source
constructed in accordance with the principles of the invention. As
shown in this figure, municipal solid waste, designated as MSW 1,
or other feedstock, is delivered, in this specific illustrative
embodiment of the invention, the system by a crane 20, which
unloads same from a truck (not specifically designated). The
feedstock can be any organic material, or fossil fuel. Crane 20
transfers MSW 1 a shredder 2. The shredded feedstock (not shown) is
then delivered a plasma chamber 6. It is be understood that any
other form of gassifier can be employed in the practice of the
invention.
[0045] The feed system, which includes shredder 2, compresses the
incoming feedstock MSW 1 so as minimize the introduction of air. An
in-line, high density flow meter 23 monitors feedstock velocity
provide instantaneous feedstock flow rate data. Plasma chamber 6,
or other conventional gassifier is, in this specific illustrative
embodiment of the invention, advantageously operated in a pyrolysis
mode, or in air and/or oxygen combustion boosted modes of
operation. Additives such as lime 4 are added, in this embodiment,
the gassifier control emissions and improve the quality of an
output slag 7.
[0046] Methods of chemically boosting heat such as with the use of
natural gas at natural gas injection port 3 can be used in the
practice of the invention. Additionally, propane injection (not
shown), or any other liquid or gaseous fuel and fuel oxidation (not
shown) can be used supplement the heat input by plasma torch 5.
[0047] In this embodiment of the invention, plasma torch 5 has its
cooling water flowing in series with feedwater inlet 10. It is be
understood that although this description is directed the use of
feedwater from a power plant, such use is merely illustrative, as
the invention can be practiced using other sources of water, such
as make up water (not shown) from a power plant or other source.
The series connection plasma torch 5 and associated components are
not shown in the figure. Such routing of the plasma torch cooling
water obviates the need for a cooling tower and increases the
overall efficiency of the plant.
[0048] A syngas product is supplied via a syngas line 21 an unlined
or refractory lined afterburner 8 extract the chemical heat from
the product gas. In this embodiment of the invention, the
afterburner is a conventional thermal oxidizer or a chamber
specifically designed combust the syngas. In other embodiments, the
afterburner will further function as a cyclone separator. A large
flow of preheated air is injected into the afterburner in a
quantity that is typically, but not always, greater than
stoichiometric. This lowers the outlet charge temperature of the
afterburner, a function that in some embodiments is critical due
the extremely high working temperatures of the plasma chamber
exhaust, which becomes the input the afterburner.
[0049] The high air flow that is injected into afterburner 8 lowers
its outlet temperature down to where a conventional heat exchanger,
which in this embodiment takes the form of a high temperature
boiler 9, extracts the heat energy. In the present embodiment, the
heat energy is transferred into a feedwater loop 10 coming from a
power plant (not shown) and is returned to the plant with
additional heat added via feedwater outlet 11. In the practice of
the invention, additional loops (not shown) and water outlets (not
shown) can in some embodiments be provided for use of make up
water.
[0050] In this specific illustrative embodiment of the invention,
the feedwater from the power plant is received at inlet 10 at a
pressure of approximately 280 psi and at a temperature of
approximately 120.degree. F. This corresponds to approximately 88
BTU/LB. After being heated in high temperature boiler 9, the
thermally enhanced feedwater that is delivered to the power plant
via feedwater outlet 11 has a pressure that remains at
approximately 280 psi, but at a temperature of approximately
400.degree. F. The thermally enhanced feedwater therefore has an
energy characteristic corresponding to approximately 376 BTU/LB.
The heat energy extracted from the MSW that is delivered to the
feedwater is used in place of fossil fuel heat energy in the power
plant, thereby increasing the thermal efficiency of the power plant
and reducing its fossil fuel consumption. Any form of heat
transfer, such as from make up water, heating, or steam generation
in heat exchanger number 9, would qualify for generation of
renewable energy.
[0051] The spent syngas continues through a bag house 12 to remove
particulates. However, in some embodiments of the invention, other
arrangements, such as precipitating filters can be used. A low
temperature heat recovery system 14 is used to preheat the
afterburner combustion air, which increases efficiency.
[0052] A sulfur removal system 15 and a mercury removal system 16
are conventional emission control devices. A blower 17 provides
pressure for the afterburner combustion air system. Blower 17 can
be variable speed or valved (not shown) to improve performance, and
is controlled by a feedback signal (not shown) responsive to the
afterburner air/fuel ratio, the afterburner outlet temperature, or
other combustion related parameters.
[0053] An induction fan 18 pulls a slight vacuum on the complete
system, and in some embodiments of the invention, is designed to
utilize a variable speed driver (not shown) to improve system
efficiency. A stack 19 is optionally employed in this embodiment as
an emergency oxidizer or a simple exhaust stack depending on the
redundancy desired in the system design.
[0054] It should be noted that no simple steam cycle generator or
Rankine cycle components are required to be used in this feedwater
or make up water system. This significantly reduces the capital
investment needed for the facility.
[0055] FIG. 2 is a simplified schematic representation of a further
embodiment of the invention. Elements of structure that have
previously been discussed are similarly designated. As shown in
this figure, a ceramic media filter 24 is used in place of bag
house 12 (in FIG. 1). The use of this ceramic media filter reduces
fouling in high temperature boiler 9, and achieves superior
reduction in emissions of particulates.
[0056] In this specific illustrative embodiment of the invention,
the filtered gas is conducted to high temperature boiler 9, where
the heat energy is extracted and transferred to feedwater or make
up water loop 10 coming from a power plant (not shown), and is
returned to the plant with additional heat added via feedwater
outlet 11, as described above in relation to FIG. 1.
[0057] Referring once again to FIG. 2, the heat-reduced syngas
product is conducted to combustion air heat recovery system 14
where the recovered heat is provided as preheat to gas afterburner
8. The further heat-reduced syngas product then is conducted to an
exhaust gas conditioning system 25, and then to a final particulate
filter 26. The filtered particulate matter is then delivered to
output slag 7, where it is removed, illustratively by a truck (not
specifically designated). The vitrification of particulate matter
renders the material essentially inert.
[0058] FIG. 3 is a simplified schematic representation of another
embodiment of this invention. Elements of structure that have
previously been discussed are similarly designated. As shown in
this figure, exhaust gas is recirculated as EGR 27 and/or EGR 28
and is used with or without excess oxidation 22 in afterburner 8 to
cool the charge (not specifically designated) and reduce harmful
emissions. Commercially available sorbents are injected into
respective ones of ports 29 and 30 to reduce emissions of SO.sub.2,
HCl, Hg, NO.sub.x, etc. and are removed by final particulate filter
26.
[0059] It is to be understood that the invention is not limited in
its application to enhancing feedwater and/or make up water for use
in a power plant, as any Rankine or other steam process, or any
process that requires heat can benefit from the energy transfer
system of the present invention
[0060] Although the invention has been described in terms of
specific embodiments and applications, persons skilled in the art
can, in light of this teaching, generate additional embodiments
without exceeding the scope or departing from the spirit of the
invention described herein. Accordingly, it is to be understood
that the drawing and description in this disclosure are proffered
to facilitate comprehension of the invention, and should not be
construed to limit the scope thereof.
* * * * *