IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
US-0997334
(2004-11-23)
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등록번호 |
US-7452392
(2008-11-18)
|
발명자
/ 주소 |
- Nick,Peter A.
- Hunnicutt,Hugh
- Peters,Robert Roy
- Anderson,Eric A.
- Dolbear,Geoffrey E.
|
출원인 / 주소 |
- Nick,Peter A.
- Hunnicutt,Hugh
- Peters,Robert Roy
- Anderson,Eric A.
- Dolbear,Geoffrey E.
|
인용정보 |
피인용 횟수 :
50 인용 특허 :
8 |
초록
▼
This invention is a reactor and a process for the conversion of organic waste material such as municipal trash, sewage, post-consumer refuse, and biomass to commercially salable materials. The invention produces the following: 1. Maximum energy conversion from the organic material 2. High volume
This invention is a reactor and a process for the conversion of organic waste material such as municipal trash, sewage, post-consumer refuse, and biomass to commercially salable materials. The invention produces the following: 1. Maximum energy conversion from the organic material 2. High volume consumption of the organic feed material 3. Less pollution of gaseous products than prior art systems 4. Solid residuals for disposal are minimal and non-hazardous. The conversion is accomplished by combining anaerobic gasification and pyrolysis of the feed organic material and making it into synthetic gas. The synthetic gas is a mixture of hydrocarbons (CxHy), hydrogen, and carbon monoxide with small amounts of carbon dioxide and nitrogen. An essential feature of the invention is a hot driver gas, devoid of free oxygen and rich in water, which supplies the entire thermal and chemical energy needed for the reactions. This hot driver gas is produced by complete sub-stoichiometric combustion of the fuel (CxHy) before it enters the reactor.
대표청구항
▼
We claim: 1. A process for the production of gaseous effluent product rich in hydrogen, carbon monoxide, and other fuel gases from a feed of heterogeneous organic material comprised of municipal trash, refuse, garbage, other post-consumer wastes or combinations thereof, which process comprises: (a)
We claim: 1. A process for the production of gaseous effluent product rich in hydrogen, carbon monoxide, and other fuel gases from a feed of heterogeneous organic material comprised of municipal trash, refuse, garbage, other post-consumer wastes or combinations thereof, which process comprises: (a) subjecting a feed of heterogeneous organic material in a single reaction chamber under conditions essentially devoid of free oxygen sufficient to gasify said heterogeneous organic material; wherein said gasification and pyrolysis occur via an upward countercurrent flow of a wet, oxygen-devoid thermal driver gas having sufficient heat and water content to effect anaerobic gasification and pyrolysis contacting directly a downward flowing moving bed of said heterogeneous organic material; wherein said driver gas is produced externally to said single reaction chamber; and (b) producing said gaseous effluent product and separating said product by conventional methods for subsequent use as a chemical feed stock or as a subsequent fuel; and (c) removing slag, in the form of liquid exiting the single reactor chamber and solidifying said slag under ambient conditions for optional subsequent use, with the proviso that in the reaction conditions of step (a), the hot driver gas is essentially devoid of free oxygen wherein the free oxygen content ranges from about 0 to less than 1000 ppm. 2. The process of claim 1, wherein depending upon the heterogeneous organic material present as the feed: the driver gas has a temperature of about 2000-3600 F at the reactor inlet in step (a); pyrolysis is performed at a temperature between 500-1200 F in step (a); gasification is performed at a temperature between 1200-2500 F in step (a); and the produced gaseous effluent exiting from the reaction chamber in step (b) has a temperature of 200-250 F. 3. The process of claim 1 wherein the driver gas has a water content of 1.1-3.5 times the molar amount of carbon formed from the pyrolysis of the heterogeneous organic material. 4. The process of claim 1 is wherein the solid feed material itself comprises up to 30% by individual volume or 75% by total accumulated volume of solid organic material selected from the group consisting of tires, wood, plastics, paper, petroleum residue, coke, charcoal, wood, forest by-products, agricultural waste, medical waste, asphalt, metals, asbestos, batteries and combinations thereof. 5. The process of claim 1 wherein the sum of heterogeneous organic material is replaced by up to about 25% of the total heterogeneous organic material by total weight selected from the group consisting of heavy oils, lube oils, waste hydrocarbons, black liquor, organic solvents, chlorinated solvents, paint, and carcinogenic organics. 6. The process of claim 1 for the production of said gaseous effluent product from a feed of heterogeneous organic material wherein the hot driver gas from an external heat source performs the following functions: (aa) gasifies the carbon in the pyrolytic residual slag of step (c) to less than 0.1 wt % of the final solid effluent via the reaction C+H2O→CO+H2, making a syngas product that adds to the total driver gas stream; (bb) liquefies the pyrolytic slag material to allow for its ultimate removal from the reaction chamber; and (cc) drying dries and removing removes water entrained by surface adsorption or other physico-chemical attraction to the feed material charged into the reaction chamber. 7. The process of claim 6 wherein the driver gas is comprised of oxygen-depleted products from any combustion process that is both (i) external to the reactor and (ii) comprised of a solid, liquid, or gaseous fuel. 8. The process of claim 1 wherein the driver gas has a chemical potential comprising a reducing atmosphere in which incidental heteroatoms, X, selected from the group consisting of chlorine, fluorine, bromine, sulfur, nitrogen and combinations thereof found in the solid feed material, are liberated by pyrolysis to form the expected acid or base gases. 9. The process of claim 1 wherein the driver gas has a fuel source comprised of natural gas; diesel oil; residual oil; wood, biomass, coal, petroleum coke, charcoal; recycled syngas; recycled white oils; or other carbonaceous material. 10. The process of claim 1 wherein the driver gas of step (a) comprises steam, exhaust from combustion turbines, exhaust from fired heaters, or the effluents from the gaseous effluent product of step (b). 11. The process of claim 1, step (b) wherein: the produced fuel gases comprise a composition of CxHy, wherein x is selected from 1 to 8 and y is selected from 4 to 12. 12. The process of claim 1 for the production of said gaseous effluent from a feed of heterogeneous organic material wherein the reaction chamber for the process further comprises: (a') identifying the types of known organic heat content such as plastic, paper, and sludge, of solid feed of said heterogeneous organic material in step (a); and (b') analyzing in step (a) exact real time feed calorific and component determination of C/H, C/O, and O/H ratios via fast neutron analysis or equivalent scanning methodology; and (c') performing statistical analysis and correlation of feed types for step (a) with easily measured bulk properties such as density; and (d') using data obtained in steps (a'), (b') and (c'), controlling the two flows of step (a) wherein said anaerobic gasification and pyrolysis occur via an upward countercurrent flow of a wet, oxygen-devoid thermal driver gas contacting directly a downward flowing moving bed of solid feed material; and (e') analyzing exact real time determination of reactor off-gas calorimetric content for step (b) via on-line spectrophotometric or GC-analysis and component analysis via GCMS analysis or appropriately calibrated spectrophotometric analyses. 13. The process of claim 12 wherein control of the reaction chamber temperature and reaction profile is accomplished by: calculation and adjustment and manipulation of oxidant flow, fuel flow, supplemental gas flow, total feed, and organic feed material content. 14. The process of claim 12 wherein the solid bed porosity and permeability in the reaction chamber are maintained by: (A) using the irregularly sized and shaped post-consumer waste material as received, (B) varying the driver gas inlet pressure to move the solid bed incrementally in order to break bridging. 15. The process of claim 12 wherein slag product flow at the bottom of the reactor is enhanced by further adding silica, alumino-silicates, alkaline earth oxides, clays, sandy sludge, or specialty papers to the feed material. 16. The process of claim 12 wherein the molten slag in the reaction chamber is removed by collection in a reservoir at the bottom of the reaction chamber and is removed using a hot tap with mud gun control as in a standard blast furnace or by dropping into a reservoir of water in which the melted material is cooled and results in a course granulated product. 17. The process of claim 12 wherein the reaction chamber is constructed of a steel or other metal shell that is lined with a sufficient amount of standard refractory material to resist the high temperature, acids, and abrasives. 18. The process of claim 12 wherein the reaction chamber is constructed in several flanged and bolted segments of 2 to 6 feet in height in a form such that fabrication, transport, installation and maintenance of each segment is easily and readily accomplished with standard construction and maintenance equipment. 19. A process for the production of gaseous effluent product rich in hydrogen, carbon monoxide, and other fuel gases as obtained from a feed of heterogeneous organic material comprised of municipal trash, refuse, garbage, or other post-consumer wastes, heavy oils, lube oils, waste hydrocarbons, black liquor, organic solvents, chlorinated solvents, paint, carcinogenic organics, tires, wood, plastics, paper, petroleum residue, coke, charcoal, forest by-products, agricultural waste, medical waste, asphalt, metals, asbestos, batteries, or combinations thereof, which process comprises: (A') subjecting a feed of a heterogeneous organic material in a single reaction chamber under conditions essentially devoid of free oxygen sufficient to gasify said heterogeneous organic material wherein said gasification and pyrolysis occur via an upward countercurrent flow of a wet oxygen-devoid thermal driver gas having sufficient heat and water content to effect anaerobic gasification and pyrolysis contacting directly a downward flowing moving bed of heterogeneous organic material and wherein said driver gas is produced externally to said single reaction chamber, thus: (B') producing effluent fuel gases of having a composition comprising methane, ethane, ethylene, propene, propane, butanes, C4H8, butadienes, pentanes, C5H10, benzene, toluene, xylenes, or combinations thereof; and: (C') generating slag, which is in the form of liquid exiting the single reactor chamber and solidifying said slag under ambient conditions for optional subsequent use.
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