IPC분류정보
| 국가/구분 |
United States(US) Patent
등록
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| 국제특허분류(IPC7판) |
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| 출원번호 |
US-0662362
(1991-02-28)
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발명자
/ 주소 |
- Keller Leonard J. (1501 N. Cedar St. Bonham TX 75418) Stanton Austin N. (1501 N. Cedar St. Bonham TX 75418)
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| 인용정보 |
피인용 횟수 :
73 인용 특허 :
0 |
초록
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Gasification, slagging, melting, and vaporizing components of waste materials and reactive carbon fuel, in variable proportions, at low pressures, using oxygen and steam reactants, effects very high temperatures, producing syngas (hydrogen and carbon monoxide), molten slag and molten metals. Integra
Gasification, slagging, melting, and vaporizing components of waste materials and reactive carbon fuel, in variable proportions, at low pressures, using oxygen and steam reactants, effects very high temperatures, producing syngas (hydrogen and carbon monoxide), molten slag and molten metals. Integration provides steam and electricity from cogeneration plants. Thermal separation of coal-methanol suspensoids, delivered by pipeline, provides reactive carbon fuel. Methanol produced from cleaned syngas and ethanol produced by corn fermentation are blended, some gasoline or diesel fuel and other additives are used, safer, cleaner-burning, cost-competitive automotive fuels are produced. Light-weight, rock-like nodules (aggregates) and rock wool are produced from slag. Recovery of metals effects optimum recycling. Some metals are produced by reducing reactions. Ethanol coproducts combined with corn, other grains, alfalfa, molasses, minerals and vitamins, provide superior feeds for ruminant animals. Byproducts of syngas cleaning are recovered and marketed. No remaining solids, no disposal problems.
대표청구항
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A process for effecting virtually complete physical and chemical restructuring of municipal solid waste, other solid wastes, and other waste materials, hereinafter referred to as “solid waste materials”, by high-temperature thermo-chemical conversion of said solid waste materials, in combination wit
A process for effecting virtually complete physical and chemical restructuring of municipal solid waste, other solid wastes, and other waste materials, hereinafter referred to as “solid waste materials”, by high-temperature thermo-chemical conversion of said solid waste materials, in combination with particulate carbon fuel which is highly reactive, and using oxygen and steam as gasification reactants, thereby producing marketable products, coproducts and byproducts, and leaving no waste solids which must be disposed of by burying in landfills or by other means of solid waste containment and storage, and releasing only minor amounts of clean inert gases to the atmosphere, said process comprising; preparing gasification feedstock materials for storage, handling and feeding into a gasifying furnace, said gasification feedstock materials comprising said solid waste materials, with the particle sizes of said solid waste materials being reduced by conventional means of fragmentation to maximum dimensions in the range of two inches to three inches, as a first said gasification feedstock material, and comprising particulate carbon fuel, which is highly reactive and which is produced from coal or lignite, as a second said gasification feedstock material; feeding said gasification feedstock materials simultaneously into said gasifying furnace, wherein simultaneous gasification, slagging, melting, and vaporizing of said gasification feedstock materials, and of mineral additives used to control the slagging process and the fluid characteristics of the molten slag, are all effected, said gasifying furnace facilitating the operation of a gasification process, utilizing the conventional and well-known gasification reactions to provide a low-pressure, high-temperature, totally-slagging gasification process; providing storage means for large quantities of said particulate carbon fuel, thus making possible substantial adjustments in the proportions of said solid waste materials and said particulate carbon fuel being fed into said gasifying furnace, thereby allowing for the accommodation of inherent day-to-day variations, seasonal variations, and year-to-year variations, in the quantities and the fuel values, of said solid waste materials which are collected, processed and used as one of said gasification feedstock materials, while maintaining ratios of the two said gasification feedstock materials within the effective limits which allow adequately controlling and continually operating said gasification process at reasonable capacity levels for effective process control and profitable operation of the processing facilities; gasifying, slagging, melting and vaporizing said gasification feedstock materials, simultaneously, and at very high gasification reaction temperatures and near-atmospheric pressures in said gasifying furnace wherein pre-mixed reactant oxygen and superheated reactant steam are used as a gasification reactant mixture, while said reactant oxygen and said superheated reactant steam are also used separately, as said gasification reactants, said gasification reactions producing syngas which is typical for such conditions, having a high hydrogen content, high carbon monoxide content, near-zero methane content, and variable, but low, carbon dioxide content, said carbon dioxide content depending in amount on the feedstock characteristics and operating conditions; converting most non-combustible solids contained in said solid waste materials, in said particulate carbon fuel, and in said mineral additives used to control the composition and fluid characteristics of said molten slag, or fluid slag, by the very high temperatures of said gasification reactions, in the range of three thousand to four thousand degrees Fahrenheit, and by the very strong reducing nature of the products of said gasification reactions, to said molten slag of low viscosity, to molten metals, and to metal vapors, collecting said molten slag in a molten slag layer near the bottom of said gasifying furnace and overlying a molten metals layer, collecting said molten metals in said molten metals layer, at the bottom of said gasifying furnace, removing said fluid slag and said molten metals separately by conventional tapping of said gasifying furnace, and recovering said fluid slag and said molten metals as valuable coproducts of said gasification process, said metal vapors being carried out of said gasifying furnace with the flow of said syngas exiting said gasifying furnace, and being condensed to powder-like metallic dust in a syngas cooling steam generator, as the temperatures of said syngas are reduced therein, and are then recovered as metallic dust in the cleaning of said syngas; controlling the mineral-chemical composition of said fluid slag by the use of appropriate said mineral additives such as silica, iron oxides, limestone, and alumina, as needed, thus maintaining low eutectic points (low melting temperatures) of said fluid slag and facilitating gravity separation of the heavier said molten metals from the lower-density, low-viscosity said fluid slag, separately removing said fluid slag and said molten metals by said tapping through conventional tap-holes at different elevations, from near the bottom of said gasifying furnace, using said mineral additives to provide some control of the quality of foamed light-weight aggregates and rock-wool insulating materials, which are produced from said fluid slag as valuable coproducts; removing said fluid slag from said molten slag layer, through said tap-holes of said gasifying furnace, and transferring said fluid slag by slag-runners to the desired location, where most of said fluid slag is poured, as controlled-diameter small streams of said fluid slag, into pools of water of controlled depths, forming rounded particles, or granules, of said light-weight aggregate, which are removed and classified as sized coproducts for subsequent use in concrete products manufacturing, for light-weight concrete construction, for roadbuilding, and for various other purposes, using some of said fluid slag for producing dense rock-like aggregate, called dense slag-rock, for crushing and screening for use as heavy aggregate for concrete construction and for railroad ballast or fill materials, and using some of said fluid slag for producing said rock-wool insulation materials by conventional blowing methods used for this purpose, thus conserving the energy generally required for melting of mineral materials to form molten mineral slags generally used in the blowing processes for the manufacture of such useful inert insulating materials; removing said molten metals through said tap-holes from said molten metals layer near the bottom of said gasifying furnace and beneath said molten slag layer, and transferring said molten metals by metal runners to casting machines, casting in molds and cooling to form metal ingots to facilitate handling, said metal ingots being usable for producing metals and alloys, or marketed as raw materials for the metal refining industries, precious metals being recovered in the metals refining operations and from metals removed from the bottom of said gasifying furnaces during outages; removing heat energy of the high temperature said syngas exiting said gasifying furnace, by heating feedwater, generating saturated steam, and superheating steam in a syngas cooling steam generator and its feedwater heater, passing a side-stream of cool syngas from said syngas cooling steam generator through a carbon monoxide shift reactor, and reacting said syngas with saturated process steam, the carbon monoxide shift reaction providing additional hydrogen in a stream of high-hydrogen syngas which is re-mixed with said syngas from said gasifying furnace, in the amounts necessary for adjusting the mole ratio of said hydrogen to said carbon monoxide of the product said syngas, to a two-to-one mole ratio of said hydrogen to said carbon monoxide, some of the heat generated in said carbon monoxide shift reactor being removed by generating saturated steam therein, said saturated steam being subsequently superheated in said syngas cooling steam generator, thus utilizing said heat energy for the purposes of preheating said feedwater, generating saturated steam from said feedwater, and superheating said saturated steam to produce superheated reactant steam for use in said gasifying furnace, the removal of said heat energy thus effecting the cooling of said syngas to the required temperatures for removal therefrom of particulate materials including said metallic dust, said syngas cooling being supplemented as required by air-cooled or water-cooled heat exchangers recovering heat energy for other purposes, or for wasting surplus said heat energy to cooling water or to the atmosphere; providing additional saturated steam, required for supplementing said saturated steam generated in said syngas cooling steam generator, and similarly used for subsequent said superheating in the same said syngas cooling steam generator, from a cogeneration electric power plant, which is made an integral part of the facilities provided, said cogeneration electric power plant also providing the electric energy required for said integrated facilities and selling surplus electric energy to utilities in the area, said additional saturated steam being provided by turbine exhaust extraction steam, used in condensing-boiling steam generators for producing said additional saturated steam, with condensate from said condensing-boiling steam generator being returned to said cogeneration electric power plant to conserve boiler feedwater for said cogeneration electric power plant, and to reduce treatment requirements and costs for said boiler feedwater, providing additional superheated steam, directly from superheated steam headers in said cogeneration electric power plant, said additional superheated steam being used for powering steam turbines driving air compressors of an air-reduction oxygen plant, providing reactant oxygen for said gasification reactions, said additional superheated steam also being used to power other steam turbines driving syngas compressors of a syngas cleaning plant and syngas compressors of a syngas compression plant, with exhaust condensate from said steam turbines being returned to said cogeneration power plant to conserve said boiler feedwater, and to reduce treatment requirements and costs for said boiler feedwater, thus improving energy utilization efficiencies and reducing operating costs for all the integrated facilities provided; cleaning and purifying hot said syngas exiting said gasifying furnace, said syngas having been cooled in said syngas-cooling steam generator and said feedwater heater, supplemented as required by said heat exchangers for cooling said syngas, by removing said particulate materials including said metallic dust, chemical impurities, and undesirable diluents therefrom, which, if not removed, would adversely affect subsequent synthesis reactions, said syngas being cleaned and purified by using the best available standard dust removal methods and equipment and gas cleaning methods and equipment, and the purified gaseous product, cleaned syngas, is then further compressed in said syngas compression plant providing pressurized clean syngas; converting said pressurized clean syngas by synthesis reaction to fuel methanol, using a standard fuel methanol plant, surplus heat energy being recovered from said fuel methanol plant, and said surplus heat energy therefrom being used for generating steam for superheating in said syngas-cooling steam generators; recovering said byproducts from said syngas cleaning plant by proven, conventional means, in forms which are marketable as byproduct materials, sulfur present in chemical compounds is converted to elemental sulfur for marketing as such, metallic dust recovered from syngas cleaning is marketed to metal refiners, carbon dioxide gas from syngas cleaning is used as inert gas and marketed for tertiary oil recovery and for other conventional uses, and nitrogen gas from syngas cleaning is used as inert gas and marketed to the cryogenics industries to the extent possible, surplus carbon dioxide and nitrogen being discharged to the atmosphere, adequate provisions are made and proper precautions are taken in all designs, processes and operations to minimize environmental impacts, the escape of undesirable effluents of any kind, or production of any solid remnants of processing which would require burying in said landfills, or disposal by said other means of waste containment and storage.
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