U.S. patent application number 13/825122 was filed with the patent office on 2013-12-12 for renewable blended natural gas and rock wool production from a plasma-based system.
The applicant listed for this patent is James C. Juranitch, Thomas R. Juranitch. Invention is credited to James C. Juranitch, Thomas R. Juranitch.
Application Number | 20130326952 13/825122 |
Document ID | / |
Family ID | 45874269 |
Filed Date | 2013-12-12 |
United States Patent
Application |
20130326952 |
Kind Code |
A1 |
Juranitch; James C. ; et
al. |
December 12, 2013 |
Renewable Blended Natural Gas and Rock Wool Production from a
Plasma-Based System
Abstract
A method and system for cost effectively converting a feedstock
using thermal plasma or other styles of gassifiers, into an energy
transfer medium using a blended gaseous fuel. The feedstock can be
any organic material or inorganic combination to generate a syngas.
The syngas is blended with any fuel of a higher thermal content
(BTU) than the syngas. The resulting blended high thermal content
fuel is used on site or reinjected into the fuel supply pipe line.
Rock wool and accessory heat are produced to increase the
efficiency of the plant.
Inventors: |
Juranitch; James C.; (Ft.
Lauderdale, FL) ; Juranitch; Thomas R.; (Delray
Beach, FL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Juranitch; James C.
Juranitch; Thomas R. |
Ft. Lauderdale
Delray Beach |
FL
FL |
US
US |
|
|
Family ID: |
45874269 |
Appl. No.: |
13/825122 |
Filed: |
September 19, 2011 |
PCT Filed: |
September 19, 2011 |
PCT NO: |
PCT/US11/01614 |
371 Date: |
August 12, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61403991 |
Sep 24, 2010 |
|
|
|
Current U.S.
Class: |
48/127.5 ;
48/180.1 |
Current CPC
Class: |
B09B 3/00 20130101; C10K
3/06 20130101; C10J 2300/0946 20130101; C10L 3/10 20130101; C10J
2300/0996 20130101; C10J 3/18 20130101; C10J 2300/0976 20130101;
C10J 2200/12 20130101; Y02P 20/133 20151101; C10L 3/003 20130101;
B09B 3/005 20130101; C10J 2300/0906 20130101; C03B 5/025 20130101;
Y02W 30/20 20150501; C10J 2300/1618 20130101; C10K 1/06 20130101;
C10J 2300/1621 20130101; C10J 3/723 20130101; C10J 2300/1238
20130101 |
Class at
Publication: |
48/127.5 ;
48/180.1 |
International
Class: |
C10K 3/06 20060101
C10K003/06 |
Claims
1. A method of extracting energy from a gassifier and delivering
the energy to an energy transfer medium, the method comprising the
steps of: extracting syngas from a gas product issued by the
gassifier; delivering the extracted syngas to a fuel blending
system; and producing a blended fuel by mixing the syngas with a
gaseous fuel, the gaseous fuel having a higher thermal (BTU)
content than the syngas.
2. The method of claim 1, wherein the gassifier is a plasma
gassifier.
3. The method of claim 1, wherein the gassifier is an inductively
heated gassifier.
4. The method of claim 1, wherein the gassifier is an inductively
heated and plasma assisted gassifier.
5. The method of claim 2, wherein there is provided the further
step of re-injecting the gas product into a gas main supply.
6. The method of claim 5, wherein there is provided the further
step of delivering the gas product to a pre-gassifier to increase
system efficiency.
7. The method of claim 6, wherein there is provided the further
step of delivering reclaimed heat to the pre-gassifier.
8. The method of claim 5, wherein the gaseous fuel includes any
combination of natural gas, butane, propane, pentane, ethane, and
any other suitable gaseous fuel.
9. The method of claim 8, wherein there is further provided the
step of controlling the thermal content of the blended fuel.
10. The method of claim 9, wherein said step of controlling the
thermal content of the blended fuel comprises the further step of
employing a sensor in a feedback loop.
11. The method of claim 10, wherein the sensor is a flame
ionization detector.
12. The method of claim 10, wherein the sensor is a calorimeter
13. The method of claim 10, wherein the sensor is a
spectrometer.
14. The method of claim 2, wherein there is further provided the
step of producing rock wool.
15. The method of claim 2, wherein there is provided the further
step of producing accessory heat.
16. The method of claim 2, wherein prior to performing said step of
extracting syngas from a gas product issued by the plasma gassifier
there are provided the further steps of: oxidizing a feedstock fuel
to produce oxidized feedstock fuel; and delivering the oxidized
feedstock fuel to the plasma gassifier, whereby a work load of a
primary heat source of the plasma gassifier is reduced.
17. A method of extracting energy from a plasma gassifier and
delivering the chemical and heat energy to an energy transfer
medium, the method comprising the steps of: extracting syngas from
a fuel product issued by the plasma gassifier; and delivering the
extracted syngas to a fuel blending system for forming a blended
fuel having a thermal content that is greater than the thermal
content of the extracted syngas.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to processes and systems
for generating a blended Natural Gas of a BTU content high enough
to be reinjected into the gas main. This is also combined with the
production of rock wool to develop a high efficiency renewable
energy plant at a low capital cost when the feedstock is renewable
such as Municipal Solid Waste (MSW). This design of plant is
becoming more desirable as high tipping fees and high
transportation costs demand small, distributed, cost effective,
MSW/renewable energy facilities.
[0003] 2. Description of the Related Art
[0004] 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.
[0005] If an analysis of plasma MSW (or other renewable fuels)
relative to other energy facilities is conducted, it becomes
apparent that the lack of existing plasma projects is not
exclusively the result of technological challenges, but also
results from the relatively poor economics associated with this
technology. Plasma technology is not inexpensive when compared to
disposition of waste using landfill, incineration, or conventional
gasification.
[0006] 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
to build a business. This is particularly problematical when one
considers that these facilities are expected to operate cost
effectively for at least thirty years.
[0007] 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 are not only complex and expensive, but
also potentially dangerous if not properly engineered. The entire
process and the facility itself thus becomes unduly expensive. Most
counties emphatically state that they do not desire large
quantities of hazardous waste to be transported through their
communities. However, large quantities of such waste must be
generated if the facility is to achieve profitability. The
production and delivery of the hazardous waste have to be carefully
coordinated since it is dangerous to store biological and other
hazardous waste feedstock.
[0008] The process and system of the present invention overcomes
the economic hurdles noted above for a plasma system. It is to be
understood, however, that the invention herein described is not
limited to the use of a plasma gassifier. In some embodiments of
the invention, conventional gassifiers, inductively heated
gassifiers, or inductively heated gassifiers with plasma assist,
can be employed. The use of a plasma gassifier in the practice of
the present invention simply increases overall system
effectiveness.
[0009] The system of the present invention is simple, flexible, and
very energy efficient. In short, it produces a large amount of
renewable energy 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.
[0010] It is, therefore, an object of this invention to provide a
simple and cost-effective renewable energy system.
[0011] It is another object of this invention to provide a
renewable energy system that can consume virtually any
feedstock.
[0012] It is also an object of this invention to provide a simple
and cost-effective renewable energy system that can use a
conventional gassifier.
[0013] It is a further object of this invention to provide a simple
and cost-effective renewable energy system that can use a plasma
gassifier.
[0014] It is yet another object of this invention to provide a
cost-effective renewable energy system that can use an inductively
heated gassifier or an inductively heated and plasma assisted
gassifier.
[0015] It is additionally an object of this invention to provide a
process and system for blending natural gas with syngas at a ratio
that can be re-injected into the natural gas main.
[0016] It is yet a further object of this invention to provide a
process and system for the production of rock wool to enhancing the
thermal and financial efficiency of the renewable energy plant.
[0017] It is yet an additional object of this invention to 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 buildings, and thereby increase the
efficiency of the renewable energy facility.
SUMMARY OF THE INVENTION
[0018] The foregoing and other objects are achieved by this
invention which provides a method of extracting energy from a
gassifier and delivering the energy to an energy transfer medium,
the method including the steps of:
[0019] extracting syngas from a gas product issued by the
gassifier;
[0020] delivering the extracted syngas to a fuel blending system;
and
[0021] producing a blended fuel by mixing the syngas with a gaseous
fuel, the gaseous fuel having a higher thermal (BTU) content than
the syngas.
[0022] In a practicable embodiment of the invention, the gassifier
is a plasma gassifier. In this embodiment, there is provided the
further step of re-injecting the gas product into a gas main
supply. Additionally, there is provided the further step of
delivering the gas product to a pre-gassifier to increase system
efficiency. Reclaimed heat is, in some embodiments, delivered heat
to the pre-gassifier. The gaseous fuel includes any combination of
natural gas, butane, propane, pentane, ethane, and any other
suitable gaseous fuel.
[0023] In an advantageous embodiment of the invention, there is
further provided the step of controlling the thermal content of the
blended fuel. The step of controlling the thermal content of the
blended fuel includes, in some embodiments, the further step of
employing a sensor in a feedback loop. The sensor can be any of a
flame ionization detector, a calorimeter, or a spectrometer.
[0024] In an efficient embodiment of the invention, there is
further provided the step of producing rock wool. In other
embodiments, there is provided the further step of producing
accessory heat.
[0025] Prior to performing the step of extracting syngas from a gas
product issued by the plasma gassifier there are provided, in some
embodiments, the further steps of:
[0026] oxidizing a feedstock fuel to produce oxidized feedstock
fuel; and
[0027] delivering the oxidized feedstock fuel to the plasma
gassifier,
[0028] whereby a work load of a primary heat source of the plasma
gassifier is reduced.
[0029] In accordance with a further method aspect of the invention,
there is provided a method of extracting energy from a plasma
gassifier and delivering the chemical and heat energy to an energy
transfer medium. In accordance with this further aspect of the
invention, there are provided the steps of:
[0030] extracting syngas from a fuel product issued by the plasma
gassifier; and
[0031] delivering the extracted syngas to a fuel blending system
for forming a blended fuel having a thermal content that is greater
than the thermal content of the extracted syngas.
[0032] The invention provides a method of producing blended natural
gas to be used on-site, or re-injected into the main, or any other
gaseous fuel, rock wool production, and accessory heat production
all at a low capital cost. This process is due in part to modern
syngas production methods. Syngas production has taken a large step
forward in quality when it is produced using a pyrolysis method
combined with plasma generated heat. This process has proven itself
to be far superior to conventional gassifiers. The thermal (BTU)
content of the product syngas can consistently be held to about 300
BTU/Cu ft. This relatively low quality fuel is a step forward for
renewable feedstock gasification but falls far short of the
requirements of modern boilers, internal combustion engines, and
turbines.
[0033] When this fuel is compared to others on a Wobbe Index it
fairs poorly. The low energy density creates a variety of
difficulties for all forms of engines or turbines. Turbine
manufacturers in particular have found it difficult to produce
energy using syngas. These prime movers also add significant cost
to any renewable energy project which makes the project less likely
to be built, or to be operated profitably.
[0034] A key attribute of the plasma based gasification system is
the ability to control the process and generate relatively
consistent thermal (BTU) content in the resultant gas. This allows
the blending of the syngas with other fuels such as natural gas to
produce a fuel of consistently high quality.
[0035] In addition to the foregoing, feedback systems are also now
available with reasonably short time constants to allow continuous
closed loop adjustments to the fuel quality. Calorimeters can now
be integrated to feed data back in minutes, and devices like flame
ionization detector (FID) units can feedback data in seconds.
[0036] When the blended natural gas invention described herein is
used in conjunction with the production of value added products
such as rock wool and facility accessory heat, a very cost
effective and efficient method of implementing renewable power is
achieved. This is a considerable asset in the endeavor to promote
the acceptance of plasma based renewable energy facilities
BRIEF DESCRIPTION OF THE DRAWING
[0037] Comprehension of the invention is facilitated by reading the
following detailed description, in conjunction with the annexed
drawing, in which FIG. 1 is a simplified schematic representation
of a process and system for generating blended natural gas from a
renewable energy source constructed in accordance with the
principles of the invention.
DETAILED DESCRIPTION
[0038] FIG. 1 is a simplified schematic representation of a process
and system 100 for generating blended natural gas from an energy
source constructed in accordance with the principles of the
invention. As shown in this figure, municipal solid waste or other
feedstock, designated as MSW 1, is delivered, in this specific
illustrative embodiment of the invention, to system 100 by a crane
2. The feedstock can be any organic material, or an inorganic mix.
Crane 2 transfers MSW 1 to a shredder 3. The shredded feedstock
(not shown) is then delivered to a pre-gassifier chamber 4. It is
to be understood that any other form of gassifier can be employed
in the practice of the invention. In this embodiment, pre-gassifier
4 helps to reduce the work of plasma torch 21, which is the primary
heat source of plasma chamber 9.
[0039] The feed system, which includes shredder 3, compresses the
incoming feedstock MSW 1 so as to minimize the introduction of air.
Plasma chamber 9, 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 5 are added, in
this embodiment, to the gassifier to control emissions and improve
the quality of an output slag 24.
[0040] Methods of chemically boosted heat such as the use of liquid
or gaseous fuels and an oxidant injected into port 6 can be used in
the practice of the invention. Additionally, any of several fuels
such as propane, recirculated syngas, ethane, butane, pentane, etc.
can be used in the practice of the invention to supplement the heat
input of plasma torch 21.
[0041] The quality of the syngas is improved in this embodiment, by
the injection of steam 25 into plasma chamber 9.
[0042] A syngas product is supplied via a syngas line 10 to a
quench system 23 to reduce particulate and other emissions and to
reduce the temperature of the syngas to a level that is acceptable
to a final syngas purification system 13. Persons skilled in the
art will realize sour water cleanup systems for the quench system
have been omitted from the drawing for the sake of clarity.
[0043] A final Heat recovery system 14 is generates heat that is
used in this embodiment to operate pre-gassifier 4. Alternatively,
in other embodiments such heat is sold as accessory heat. Heat
produced by quench system 11 can also be sold or delivered to the
pre-gassifier. A cooling tower for the facility has been omitted
from this figure for the sake of clarity.
[0044] Compressor 15 draws a slight vacuum on system 100 and
directs the syngas to a three way valve 26 and a calorimeter 16. In
other embodiments, other fuel quality measuring devices, such as a
flame ionization detector (FID), can be used in the practice of the
invention. The syngas in line 17 is directed to a blending valve 27
that mixes natural gas 18, or any other fuel such as ethane,
propane, butane, pentane etc. Mixing valve 27 is employed in a
closed loop control arrangement that maintains a quality of fuel
appropriate for re-injection into a natural gas main 29. Thus,
typically about 5% to 10% concentration of syngas is utilized in
this embodiment. It should be understood this invention is not
limited to 5% to 10% blend concentrations. The product gas is
pressurized by compressor 28 prior to being re-injected into gas
main 29.
[0045] Financial productivity and overall system efficiency of the
plant are enhanced by spinning or blowing slag 24 into rock wool by
apparatus 30. The rock wool is then shipped by truck 31.
[0046] 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 and claimed 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.
* * * * *