WO2024182640A2 - Coaxially stacked coaxial fuel gasifier - Google Patents
Coaxially stacked coaxial fuel gasifier Download PDFInfo
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- WO2024182640A2 WO2024182640A2 PCT/US2024/017924 US2024017924W WO2024182640A2 WO 2024182640 A2 WO2024182640 A2 WO 2024182640A2 US 2024017924 W US2024017924 W US 2024017924W WO 2024182640 A2 WO2024182640 A2 WO 2024182640A2
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- gasification
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- char combustion
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
- C10J3/72—Other features
- C10J3/82—Gas withdrawal means
- C10J3/84—Gas withdrawal means with means for removing dust or tar from the gas
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
- C10J3/46—Gasification of granular or pulverulent flues in suspension
- C10J3/48—Apparatus; Plants
- C10J3/482—Gasifiers with stationary fluidised bed
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
- C10J3/72—Other features
- C10J3/723—Controlling or regulating the gasification process
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
- C10J3/72—Other features
- C10J3/726—Start-up
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
- C10K1/00—Purifying combustible gases containing carbon monoxide
- C10K1/002—Removal of contaminants
- C10K1/003—Removal of contaminants of acid contaminants, e.g. acid gas removal
- C10K1/005—Carbon dioxide
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
- C10K1/00—Purifying combustible gases containing carbon monoxide
- C10K1/02—Dust removal
- C10K1/026—Dust removal by centrifugal forces
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
- C10K1/00—Purifying combustible gases containing carbon monoxide
- C10K1/08—Purifying combustible gases containing carbon monoxide by washing with liquids; Reviving the used wash liquors
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
- C10K1/00—Purifying combustible gases containing carbon monoxide
- C10K1/08—Purifying combustible gases containing carbon monoxide by washing with liquids; Reviving the used wash liquors
- C10K1/085—Purifying combustible gases containing carbon monoxide by washing with liquids; Reviving the used wash liquors two direct washing treatments, one with an aqueous liquid and one with a non-aqueous liquid
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- C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
- C10K3/00—Modifying the chemical composition of combustible gases containing carbon monoxide to produce an improved fuel, e.g. one of different calorific value, which may be free from carbon monoxide
- C10K3/02—Modifying the chemical composition of combustible gases containing carbon monoxide to produce an improved fuel, e.g. one of different calorific value, which may be free from carbon monoxide by catalytic treatment
- C10K3/04—Modifying the chemical composition of combustible gases containing carbon monoxide to produce an improved fuel, e.g. one of different calorific value, which may be free from carbon monoxide by catalytic treatment reducing the carbon monoxide content, e.g. water-gas shift [WGS]
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- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J2300/00—Details of gasification processes
- C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
- C10J2300/0913—Carbonaceous raw material
- C10J2300/0916—Biomass
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- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J2300/00—Details of gasification processes
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- C10J2300/093—Coal
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- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J2300/00—Details of gasification processes
- C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
- C10J2300/0913—Carbonaceous raw material
- C10J2300/0946—Waste, e.g. MSW, tires, glass, tar sand, peat, paper, lignite, oil shale
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- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J2300/00—Details of gasification processes
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- C10J2300/0953—Gasifying agents
- C10J2300/0973—Water
- C10J2300/0976—Water as steam
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- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J2300/00—Details of gasification processes
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- C10J2300/0983—Additives
- C10J2300/0986—Catalysts
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- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J2300/00—Details of gasification processes
- C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
- C10J2300/0983—Additives
- C10J2300/0989—Hydrocarbons as additives to gasifying agents to improve caloric properties
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- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J2300/00—Details of gasification processes
- C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
- C10J2300/0983—Additives
- C10J2300/0993—Inert particles, e.g. as heat exchange medium in a fluidized or moving bed, heat carriers, sand
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- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J2300/00—Details of gasification processes
- C10J2300/12—Heating the gasifier
- C10J2300/1246—Heating the gasifier by external or indirect heating
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- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J2300/00—Details of gasification processes
- C10J2300/16—Integration of gasification processes with another plant or parts within the plant
- C10J2300/1603—Integration of gasification processes with another plant or parts within the plant with gas treatment
- C10J2300/1606—Combustion processes
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- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J2300/00—Details of gasification processes
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- C10J2300/1625—Integration of gasification processes with another plant or parts within the plant with solids treatment
- C10J2300/1637—Char combustion
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- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J2300/00—Details of gasification processes
- C10J2300/16—Integration of gasification processes with another plant or parts within the plant
- C10J2300/164—Integration of gasification processes with another plant or parts within the plant with conversion of synthesis gas
- C10J2300/1643—Conversion of synthesis gas to energy
- C10J2300/165—Conversion of synthesis gas to energy integrated with a gas turbine or gas motor
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J2300/00—Details of gasification processes
- C10J2300/16—Integration of gasification processes with another plant or parts within the plant
- C10J2300/164—Integration of gasification processes with another plant or parts within the plant with conversion of synthesis gas
- C10J2300/1656—Conversion of synthesis gas to chemicals
- C10J2300/1665—Conversion of synthesis gas to chemicals to alcohols, e.g. methanol or ethanol
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J2300/00—Details of gasification processes
- C10J2300/16—Integration of gasification processes with another plant or parts within the plant
- C10J2300/1693—Integration of gasification processes with another plant or parts within the plant with storage facilities for intermediate, feed and/or product
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- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J2300/00—Details of gasification processes
- C10J2300/18—Details of the gasification process, e.g. loops, autothermal operation
- C10J2300/1807—Recycle loops, e.g. gas, solids, heating medium, water
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- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J2300/00—Details of gasification processes
- C10J2300/18—Details of the gasification process, e.g. loops, autothermal operation
- C10J2300/1853—Steam reforming, i.e. injection of steam only
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- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
- C10K1/00—Purifying combustible gases containing carbon monoxide
- C10K1/08—Purifying combustible gases containing carbon monoxide by washing with liquids; Reviving the used wash liquors
- C10K1/10—Purifying combustible gases containing carbon monoxide by washing with liquids; Reviving the used wash liquors with aqueous liquids
- C10K1/101—Purifying combustible gases containing carbon monoxide by washing with liquids; Reviving the used wash liquors with aqueous liquids with water only
Definitions
- Embodiments of the present disclosure generally relate to a gasification system for gasifying various feedstocks. Description of the Related Art [0003] Numerous efforts are being made to produce highly efficient power generation systems which employ fossil fuel, waste material and other biomasses as fuel.
- IGCC integrated gasification combined cycle
- Conventional IGCC systems include twin tower circulation type gasification furnaces or two-bed pyrolysis reactor systems having two furnaces, e.g., a gasification furnace and a char combustion furnace. These systems often include a fluidizing medium and char that is circulated between the gasification furnace and the char combustion furnace.
- the present disclosure is directed to a coaxially integrated gasification furnace.
- the coaxially integrated gasification furnace includes a gasification chamber fluidly connected to a gasification cyclone separator.
- the coaxially integrated gasification furnace also includes a char combustion chamber fluidly connected to a combustion cyclone separator, in which the char combustion chamber is located within the gasification chamber, and/or positioned coaxially therewith.
- a settling isolation chamber is located near the char combustion chamber and is separated by a first partition and a second partition from the gasification chamber and the combustion chamber.
- the present disclosure is directed to a gasification system.
- the gasification system includes a coaxially integrated gasification furnace fluidly coupled to an air supply line and a steam supply line. One or more valves couple each of the air supply line and the steam supply line to the coaxially integrated gasification furnace.
- the coaxially integrated gasification PATENT Attorney Docket No.: ACHM/0002PC furnace includes a gasification chamber fluidly coupled to a gasification cyclone separator.
- a char combustion chamber is fluidly coupled to a combustion cyclone separator. The char combustion chamber is located within the gasification chamber.
- the gasification furnace includes a settling isolation chamber having a first partition and a second partition.
- the first partition separates the settling isolation chamber from the combustion chamber
- the second partition separates the settling isolation chamber from the gasification chamber.
- the gasification furnace includes at least a temperature control element disposed on the settling isolation chamber.
- the present disclosure is directed to a method of gasifying fuel sources.
- the method includes heating a fluidizing medium in a gasification chamber, a char combustion chamber, and a settling isolation chamber of a gasification system to a temperature of about 500 °C to about 1000 °C by introducing a steam.
- a fuel source is injected to the gasification chamber.
- the fuel source is gasified by contacting the fuel source with the fluidizing medium in the gasification chamber.
- a product gas is obtained from the gasification chamber.
- a residual carbonized char and a portion of the fluidizing medium are directed to an overflow chute of the gasification chamber.
- the overflow chute is fluidly coupled to the char combustion chamber.
- the residual carbonized char and the portion of the fluidizing medium are heated in the char combustion chamber.
- An exhaust gas is obtained from the char combustion chamber.
- the portion of the fluidizing medium is collected in the settling isolation chamber.
- the portion of the fluidizing medium in the settling isolation chamber is directed to the gasification chamber by flowing one or more gases from an air supply line to the settling isolation chamber or the char combustion chamber.
- FIG. 1 is a schematic diagram illustrating a coaxially integrated gasification furnace, according to at least an embodiment of the disclosure.
- Figure 2 is a schematic diagram illustrating a system for reforming a fuel source using a coaxially integrated gasification furnace, according to at least an embodiment of the disclosure.
- Figure 3 is a schematic diagram illustrating a system for producing electrical power using a coaxially integrated gasification furnace, according to at least an embodiment of the disclosure.
- Figure 4 is a schematic diagram illustrating a system for capturing carbon using a gasifier, according to at least an embodiment of the disclosure.
- Figure 5 is a schematic diagram illustrating a gasification system, according to at least an embodiment of the disclosure.
- Figure 6 is a flow diagram illustrating a method of operating a gasification system, according to at least an embodiment of the disclosure.
- Figure 7 is a flow diagram illustrating a method of gasifying a fuel source, according to at least an embodiment of the disclosure.
- Figures 8A and 8B are graphs illustrating an energy consumption and/or lower heating value (LHV) relative to temperature, according to at least one embodiment of the disclosure.
- Figure 8A is a graph illustrating an energy consumption relative to temperature.
- Figure 8B is a graph illustrating an LHV relative to temperature.
- Figure 9 is a graph illustrating an LHV relative to varying steam to fuel source ratios, according to at least one embodiment of the disclosure.
- Figure 10 is a graph illustrating varying concentrations of a product gas composition, according to at least one embodiment of the disclosure.
- Figures 11A and 11B are graphs illustrating gasifier system efficiency, according to at least an embodiment of the disclosure.
- Figure 10A is a graph illustrating a cold gas efficiency.
- Figure 10B is a graph illustrating a hot gas efficiency.
- Figures 12A and 12B are diagram illustrating a fluidizing medium particle size efficiency, according to at least an embodiment of the disclosure.
- Figure 12A is a diagram illustrating a first fluidizing medium particle size.
- Figure 12B is a diagram illustrating a second fluidizing medium particle size.
- FIG. 1 schematically shows the basic structure of a coaxially integrated gasification furnace 100.
- a coaxially integrated gasification furnace including a gasification chamber 101, a combustion chamber 102, a gasification cyclone separator 103, and a char combustion cyclone separator 104 for performing three respective functions including: pyrolysis and/or steam reforming due to the presence of steam and absence of oxygen due to the PATENT Attorney Docket No.: ACHM/0002PC coaxial arrangement of the gasification chamber and the char combustion chamber , char combustion, and product recovery.
- the gasification chamber 101 and the combustion chamber 102 are housed coaxially in a furnace such that the gasification chamber 101 is located outside of coaxial arrangement below and/or concentric with the combustion chamber 102.
- the gasification chamber 102 includes a fluidized bed positioned in a coaxially outer region, which contains a of fluidizing medium (e.g., an abrasion resistant material such as sand such as silica sand or refractory sand, e.g., olivine or molochite).
- a of fluidizing medium e.g., an abrasion resistant material such as sand such as silica sand or refractory sand, e.g., olivine or molochite.
- the fluidizing medium can include one or more catalytically active elements capable of absorbing one or more infrared wavelengths of light.
- the fluidizing medium may include an element capable of absorbing an infrared wavelength of light such that the fluidizing medium absorbs thermal energy when flowing through the system 100.
- the gasification chamber 102 can include about 5 kg to about 8 kg of the fluidizing medium, e.g., about 5 kg to about 7 kg, about 5.5 kg to about 6.8 kg, or about 6.4 kg to about 6.7 kg.
- the fluidizing medium can fill a volume of about 0.001 m 3 to about 0.01 m 3 of the gasification chamber 102, e.g., about 0.001 m 3 to about 0.009 m 3 , about 0.002 m 3 to about 0.006 m 3 , or about 0.005 m 3 to about 0.006 m 3 .
- the fluidizing medium can include a particle size of about 100 ⁇ m to about 5000 ⁇ m, e.g., about 100 ⁇ m to about 4000 ⁇ m, about 250 ⁇ m to about 2500 ⁇ m, about 100 ⁇ m to about 500 ⁇ m, or about 2000 ⁇ m to about 3000 ⁇ m.
- the fluidizing medium can include a density of about 1000 kg/m 3 to about 2000 kg/m 3 , e.g., about 1000 kg/m 3 to about 1800 kg/m 3 , about 1100 kg/m 3 to about 1600 kg/m 3 , about 1150 kg/m 3 to about 1500 kg/m 3 , or about 1200 kg/m 3 to about 1300 kg/m 3 .
- fluidized medium adds catalytic reaction and/or supplemental heat generation.
- the fluidized medium may produce a gas, a light combustible, a heavy combustible, and a heavy incombustible (e.g., PATENT Attorney Docket No.: ACHM/0002PC metals) as a result of a fuel source, described below.
- the light combustible may have a specific gravity that is less than the specific gravity of the fluidizing medium, in which the light combustible may rise to the top of the fluidized bed. The light combustible may then fall through the overflow chute, described below.
- the heavy combustible and heavy incombustible may remain at the bottom of the fluidized bed.
- the heavy combustible and heavy incombustible may be retrieved from a lower collection site of the gasification chamber.
- the fluidizing medium is held in a fluidizing state by the fluidizing gas, and a splash zone, positioned coaxially above the dense bed, which contains both the fluidizing medium and a large amount of gases, with the fluidizing medium splashing violently.
- Above the fluidized bed e.g., above the splash zone, there is a gasification cyclone separator 103 which contains almost no fluidizing medium, but is primarily made up of gases, e.g., product gases and/or gasification gases such as carbon monoxide, carbon dioxide, methane, alkanes, alkenes, alkylenes, nitrogen, sulfur, and a combination thereof.
- the gasification cyclone separator 103 separates one or more gases from one or more particles, e.g., sand such as silica sand or refractory sand, e.g., olivine or molochite.
- a cyclone separator may separate one or more particulates, e.g., sand such as silica sand or refractory sand, e.g., olivine or molochite, from a gas as a result of inertia.
- the gasification gas enters the gasification cyclone separator 103, in which a spiral vortex is formed due to the tangentially ejecting gas mixture port and conical shape of the cyclone separator.
- Lighter components and gas e.g., carbon monoxide, carbon dioxide, methane, alkanes, alkenes, alkylenes, nitrogen, sulfur, and a combination thereof, continue to flow and exit the cyclone separator as product gas 112, in which heavier components, e.g., sand such as silica sand or refractory sand, e.g., olivine or molochite, fall back towards the fluidized bed of the gasification chamber as a result of inertia loss.
- sand such as silica sand or refractory sand, e.g., olivine or molochite
- the fluidizing medium may absorb one or more infrared PATENT Attorney Docket No.: ACHM/0002PC wavelengths of light while falling back towards the fluidized bed, such that the fluidizing medium may activate the fuel source immediately upon contact in the gasification chamber.
- the product gas 112 comprises one or more volatile organic compounds (VOCs).
- the VOCs can include an oxygen-free VOC and/or an oxygenated VOC.
- an oxygen-free gas can include a gas which does not contain any oxygen, e.g., alkanes, such as methane, ethane, propane, butane, pentane, hexane, heptane, octane, nonane, decane, or a combination thereof, alkenes, such as ethylene, propylene, butylene, pentylene, hexene, heptene, octene, nonene, decene, or a combination thereof, or alkylenes, such as ethyne, propyne, or the like, or nitrogen.
- alkanes such as methane, ethane, propane, butane, pentane, hexane, heptane, octane, nonane, decane, or a combination thereof
- alkenes such as ethylene, propylene, butylene, pentylene, hexen
- an oxygenated VOC can include carbon monoxide, carbon dioxide, diatomic oxygen, nitrogen oxide, water vapor (steam), or a combination thereof.
- the product gas 112 can include a lower heating value (LHV), e.g., net calorific value, expressed in Mega-Joules (MJ) per normal cubic meter of gas (Nm 3 ), of about 5 MJ/Nm 3 to about 30 MJ/Nm 3 , e.g., about 5 MJ/Nm 3 to about 25 MJ/Nm 3 , about 10 MJ/Nm 3 to about 20 MJ/Nm 3 , or about 15 MJ/Nm 3 to about 19.5 MJ/Nm 3 .
- LHV lower heating value
- the gasification cyclone separator 103 can emit about 1.0 kg/hr to about 2,000 kg/hr of product gases 112, e.g., about 1.0 kg/hr to about 2,000 kg/hr, about 1.2 kg/hr to about 1,500 kg/hr, or about 1.4 kg/hr to about 1,000 kg/hr.
- about 0.1 Nm 3 /kW to about 0.3 Nm 3 /kW of the product gas can be emitted by the gasification cyclone separator 103, e.g., about 0.1 Nm 3 /kW to about 0.25 Nm 3 /kW, about 0.15 Nm 3 /kW to about 0.2 Nm 3 /kW, or about 0.17 Nm 3 /kW to about 0.19 Nm 3 /kW.
- about 1.0 Nm 3 /kg to about 5.0 Nm 3 /kg of the product gas can be emitted by the gasification cyclone separator 103, e.g., about 1.0 Nm 3 /kg to about 4.0 Nm 3 /kg, about 1.5 Nm 3 /kg to about 3.5 Nm 3 /kg, or about 2.0 Nm 3 /kg to about 2.2 Nm 3 /kg.
- about 1.0 Nm 3 /kg to about PATENT Attorney Docket No.: ACHM/0002PC 5.0 Nm 3 /kg of the product gas can be emitted by the gasification cyclone separator 103, e.g., about 1.0 Nm 3 /kg to about 4.0 Nm 3 /kg, about 1.5 Nm 3 /kg to about 3.5 Nm 3 /kg, or about 2.0 Nm 3 /kg to about 2.2 Nm 3 /kg.
- the char combustion chamber 102 is located within the gasification chamber 101, in which the char combustion chamber 102 extends downward coaxially from the furnace ceiling.
- the char combustion chamber 102 may be a cylinder or conically shaped reservoir that extends from the ceiling of the furnace.
- the combustion chamber 102 may be located inside the gasification chamber 101, in which a portion of the combustion chamber 102 is located within the fluidizing bed of the gasification chamber 101.
- the gasification chamber 101 and the char combustion chamber 102 are divided by walls such that each chamber does not interact with one another.
- a wall of the char combustion chamber can include a transparent wall, e.g., a wall that may allow one or more infrared wavelengths of light to pass through.
- the transparent wall can include quartz, alumina, silicon, silicon carbide, diamond, or any other suitable material that allows infrared and/or thermal energy to transmit through the char combustion chamber wall.
- a transparent wall may allow for the fluidizing medium to absorb heat while flowing throughout the char combustion chamber.
- the char combustion wall may include a hardness and/or abrasion resistance to prevent the fluidizing media from degrading the char combustion wall.
- a combustion cyclone separator 104 is located directly above the combustion chamber 102.
- the combustion cyclone separator 104 separates one or more gases from one or more particles existing in the combustion PATENT Attorney Docket No.: ACHM/0002PC chamber, as described above.
- the combustion cyclone separator 104 may separate one or more particulates, e.g., sand such as silica sand or refractory sand, e.g., olivine or molochite, from exhaust gases 113 emitted from the combustion chamber 102.
- Particulates e.g., sand such as silica sand or refractory sand, e.g., olivine or molochite
- sand such as silica sand or refractory sand, e.g., olivine or molochite
- the settling isolation chamber 105 separates the combustion chamber 102 from the gasification chamber 101.
- the exhaust gases 113 can include carbon dioxide, nitrogen, nitrogen oxide, water, or a combination thereof.
- the exhaust gases 113 can include a temperature of about 800 °C to about 1100 °C, e.g., about 800 °C to about 1000 °C, about 950 °C to about 950 °C, or about 900 °C to about 950 °C.
- the combustion cyclone separator 104 can emit about 1.0 kg/hr to about 3.0 kg/hr of exhaust gases 113, e.g., about 1.0 kg/hr to about 2.5 kg/hr, about 1.2 kg/hr to about 2.0 kg/hr, or about 1.4 kg/hr to about 1.6 kg/hr.
- the combustion cyclone separator 104 can emit about 1.0 kg/day to about 20 tons/day of exhaust gases 113, e.g., about 1.0 kg/day to about 18 tons/day, about 5.0 kg/day kg/hr to about 15 tons/day, or about 10 kg/day to about 10 tons/day.
- the gasification chamber 101, the char combustion chamber 102, the gasification cyclone separator 103 and the combustion cyclone separator 104 are disposed in one fluidized-bed furnace, with the char combustion chamber 102 being located above the gasification chamber 101, the gasification cyclone separator 103 and the combustion cyclone separator 104 being positioned above the char combustion chamber 102.
- the settling isolation chamber 105 acts to settle fluidizing medium.
- the settling isolation chamber 105 includes a settled fluidized bed such that a PATENT Attorney Docket No.: ACHM/0002PC “U trap” is be formed to prevent one or more combustion gases from entering the gasification chamber 101 and/or one or more gasification gases from entering the combustion chamber 102.
- the settling isolation chamber 105 may include a section of the combustion chamber 102 which is in contact with the gasification chamber 101 as a function of the buildup of the fluidized medium overflowing and falling into the gasification chamber 101. As such, the char combustion chamber 102 is separated into the settling isolation chamber 105 and another portion of the char combustion chamber, the main char combustion chamber.
- the settling isolation chamber 105 is divided from the main char combustion chamber by a partition wall.
- the settling isolation chamber 105 and the gasification chamber 101 are divided from each other by a second partition wall, which prevents gases from entering the combustion chamber.
- the char combustion chamber 102 may be operated at a temperature range of about 500 °C to about 1000 °C, e.g., about 500 °C, about 600 °C, about 700 °C, about 800 °C, about 900 °C, about 1000 °C. In an embodiment, the char combustion chamber 102 may be operated at a temperature of about 850 °C.
- the gasification chamber 101 may be operated at a temperature range of about 500 °C to about 1000 °C, e.g., about 500 °C, about 600 °C, about 700 °C, about 800 °C, about 900 °C, about 1000 °C. In an embodiment, the gasification chamber 101 may be operated at a temperature of about 650 °C.
- the char combustion chamber 102 may be operated at a pressure range of about 0.5 atm to about 10 atm, e.g., about 0.5 atm to about 10 atm, about 1 atm to about 8 atm, about 1 atm to about 5 atm, or about 1.5 atm to about 2.0 atm. In an embodiment, the char combustion chamber 102 may be operated at a pressure of about 1.5 atm.
- the gasification chamber 101 may be operated at a pressure range of 0.5 atm to about 10 atm, e.g., about 0.5 atm to about 10 atm, about 1 atm to about 8 atm, about 1 atm to about 5 atm, or about 1.5 atm to about 2.0 atm. In an embodiment, the gasification chamber 101 may be operated at a temperature of about 1.0 atm.
- PATENT Attorney Docket No.: ACHM/0002PC [0040]
- the char combustion chamber 102 is heated by a heat source 106. While FIG.1 shows the heat source 106 in the char combustion chamber, the heat source 106 may also introduce heat and/or steam to the gasification chamber 101 (not shown).
- the heat source 106 may include any steam or heat exchanger mechanism as described in the present disclosure, e.g., microwave radiation or inductive heating.
- the steam may be introduced to the gasification chamber 101 or the char combustion chamber 102 via the heat source 106 at a steam mass flow rate of about 0.05 kg/hr to about 1,200 kg/hr, e.g., about 0.05 kg/hr to about 1,100 kg/hr, about 1.2 kg/hr to about 1,000 kg/hr, or about 300 kg/hr to about 1,200 kg/hr.
- the steam may be introduced to the gasification chamber 101 or the char combustion chamber 102 via the heat source 106 at a steam volume flow rate of about 5 m 3 /hr to about 15 m 3 /hr, e.g., about 5 m 3 /hr to about 12 m 3 /hr, about 8 m 3 /hr to about 12 m 3 /hr, or about 11 m 3 /hr to about 12 m 3 /hr.
- the steam may be introduced at a pressure of about 1 atm to about 2.0 atm, e.g., about 1.0 atm to about 1.8 atm, about 1.2 atm to about 1.7 atm, about 1.3 atm to about 1.6 atm, or about 1.4 atm to about 1.6 atm.
- the steam can be introduced at a temperature of about 200 °C to about 1000 °C, e.g., about 200 °C, about 300 °C , about 400 °C , about 500 °C, about 600 °C, about 700 °C, about 800 °C, about 900 °C, or about 1000 °C.
- the steam can include an enthalpy of about 5000 KJ to about 9000 KJ, e.g., about 5000 KJ to about 8000 KJ, about 6000 KJ to about 7800 KJ, or about 7000 KJ to about 7780 KJ.
- the steam temperature introduced via the heat source 106 controls the temperature of the char combustion chamber 102 and/or the gasification chamber 101.
- the heat source 106 introduces steam to the char combustion chamber 102 to operate the char combustion chamber 102 at a temperature of about 850 °C.
- the heat source 106 introduces steam to the gasification chamber 101 to operate the gasification chamber 101 at a temperature of about 650 °C.
- the heat source 106 may heat the fluidizing medium of the gasification chamber 101 such that the fluidizing medium has a temperature of about 650 °C to about 1000 °C, e.g., about 700 °C to about 900 °C, about 750 °C to about 850 °C, or about 800 °C to about 850 °C.
- the heat source 106 may heat the fluidizing medium of the gasification chamber 101 such that the fluidizing medium has a thermal energy of about 4000 KJ to about 6000 KJ, e.g., about 4000 KJ to about 5500KJ, about 4500 KJ to about 5200 KJ, or about 5000 KJ to about 5100 KJ.
- the fluidizing medium that has been heated in the char combustion chamber 102 flows into the combustion cyclone separator 104 and falls into the settling isolation chamber 105. The fluid medium can build up in the settling isolation chamber 105 and over flow into the gasification chamber 101.
- the settling isolation chamber 106 includes temperature control elements 107.
- the temperature control elements 107 may heat or cool the temperature of the fluidized medium and/or the gasification chamber to maintain a temperature of about 200 °C to about 850 °C, e.g., about 200 °C to about 800 °C, about 250 °C to about 700 °C, or about 250 °C to about 650 °C.
- the temperature control elements 107 may include a source of heating, e.g., steam, microwave radiation, inductive heating, or a combination thereof.
- the temperature control elements 107 may include iron containing particles heated by inductively coupled radio frequency (RF).
- RF radio frequency
- the Fe containing particles may be heated by microwave, induction heating, infrared, resistive heating, or the like.
- An overflow chute 108 exists within the gasification chamber 101.
- the temperature control elements 107 can include introducing steam at a pressure of about 1.0 atm to about 2.0 atm, a temperature of about 200 °C to about 850 °C, and a mass flow rate of about 1.0 kg/hr to about 2.0 kg/hr.
- An overflow chute 108 exists within the gasification chamber 101.
- the overflow chute 108 is a channel located in the fluidized bed of the PATENT Attorney Docket No.: ACHM/0002PC gasification chamber 101.
- the overflow chute 108 extends upwardly from the fluidized bed of the gasification chamber 101 upwards towards the splash zone.
- the channel has an orifice located above the fluidized bed of the gasification chamber 101.
- the orifice allows fluidized medium that is falling from the settling isolation chamber 105 to enter the channel.
- the overflow chute extends through the fluidized bed towards the char combustion chamber 102, such that the particulates are transported back towards an air supply line 109 of the char combustion chamber 102.
- the air supply line 109 provides one or more gases, e.g., air or inert gases such as argon, helium, nitrogen, or a combination thereof.
- the air supply line 109 can provide about 0.5 kg/hr to about 2,000 kg/hr of the one or more gases, e.g., about 0.5 kg/hr to about 9.7 kg/hr, about 0.7 kg/hr to about 9.7 kg/hr, about 1.2 kg/hr to about 9.7 kg/hr, or about 9.0 kg/hr to about 9.7 kg/hr.
- the air supply line 109 may supply one or more gases to any of the components of the system 100, e.g., the gasification chamber 101, the char combustion chamber 102, the temperature control element 107, the settling isolation chamber 105, the heat source 106, and/or the fuel source 110.
- the air supply line 109 provides the one or more gases to inject additional fluidized medium into the combustion chamber 102, thereby providing a recirculation of the fluidized medium in the system 100.
- the air supply line 109 can allow for an enhanced control of the flow of fluidizing medium between the gasification chamber 101 and the char combustion chamber 102.
- the air supply line 109 can provide the recirculation of the fluidized medium in the system 100 by pulsing one or more of the gases at a pulse rate of 0.1 s to about 30 s, e.g., about 0.1 s to about 25 s, about 1 s to about 20 s, about 5 s to about 15 s, or about 8 s to about 10 s.
- the air supply line 109 can provide one or more gases as either an oxidizer gas or a pneumatic transportation, thereby providing control of combustion PATENT Attorney Docket No.: ACHM/0002PC stoichiometry to promote either greater combustion and/or movement of the fluidizing medium.
- fluidized medium may build up in the channel of the overflow chute 108 to prevent gasification gas from traveling through the overflow chute 108 and into the combustion chamber 102.
- the gasification chamber 101 and the char combustion chamber 102 are divided from each other by the partition walls such that no gases flow there between.
- a fuel source 110 e.g., coal, waste, biomass, or the like is injected into the gasification chamber 101 via an airtight dispenser and/or feed stock.
- the fuel source can include one or more polymers, e.g., polyethylene, polypropylene, polystyrene, or a combination thereof.
- the fuel source 110 can include an LHV, e.g., a net calorific value, of about 50,000 KJ to about 200,000 KJ, e.g., about 50,000 KJ to about 180,000 KJ, about 80,000 KJ to about 150,000 KJ, or about 90,000 KJ to about 100,000 KJ.
- the fuel source can be injected to provide a hydrogen content of about 0.1 kg/hr to about 0.5 kg/hr, e.g., about 0.1 kg/hr to about 0.4 kg/hr, about 0.2 kg/hr to about 0.4 kg/hr, or about 0.2 kg/hr to about 0.3 kg/hr.
- the fuel source 110 can be injected at a flow rate of about 2 kg/day to about 20 kg/day, e.g., about 2.1 kg/day to about 20 tons/day, about 10 kg/day to about 18 kg/day, or about 15 kg/day to about 20 kg/day.
- the fuel source 110 can be injected into the gasification chamber 101 to provide a carbon content flow of about 1.0 kg/hr to about 2.1 kg/hr, e.g., about 1.0 kg/hr to about 2.0 kg/hr, about 1.5 kg/hr to about 2.0 kg/hr, or about 1.7 kg/hr to about 2.0 kg/hr.
- the fuel source 110 can be introduced to the gasification chamber 101 via a plurality of airtight dispensers and/or feed stocks (not shown).
- a first fuel source can be introduced via a first airtight dispenser and/or feed stock, in which a second fuel source can be introduced via second airtight dispenser and/or feed stock.
- a plurality of feedstocks can allow for enhanced throughout of the gasifier system, thereby increasing the total amount of product gas.
- the steam from the heat source 106 and the fuel source 110 can be introduced at a ratio of about 0.5 to about 5.0 of steam to fuel source 110, e.g., about 0.5 to about 4.75, about 0.75 to about 3.5, or about 1.0 to about 1.5.
- the steam from the heat source 106 and the fuel source 110 can be introduced to provide a steam to carbon ratio of 1.0 to about 5.0, e.g., about 1.0 to about 4.8, about 1.2 to about 2.6, or about 1.4 to about 1.5.
- the fuel source 110 is heated by the fluidizing medium in the gasification chamber 101 to a temperature of about 500 °C to about 1000 °C, e.g., about 500 °C, about 600 °C, about 700 °C, about 800 °C, about 900 °C, about 1000 °C.
- the fuel source 110 can be heated by the fluidizing medium, pyrolyzed, and gasified in the gasification chamber 101.
- the fuel source 110 is carbonized in the gasification chamber 101.
- volatile components of the fuel sources injected into the gasification chamber 101 may be instantaneously gasified, and then solid carbon (char) may be gasified relatively slowly compared to the volatile components.
- the airtight dispenser may be equipped with dehydration means such as vacuum pump and/or super critical CO2.
- dehydration means such as vacuum pump and/or super critical CO2.
- residual carbonized char or lighter components may flow into the combustion chamber through the overflow chute 108.
- the light components or char introduced from the gasification chamber 101 is combusted in the char combustion chamber 102, in which steam 111 is produced.
- the steam 111 may be reintroduced to the gasification chamber 101 as a heat source for the fluidizing medium through a plurality of steam orifices located within the fluidizing medium.
- the fluidizing medium in the overflow chute 108 and/or the settling isolation chamber 105 can provide a seal between the PATENT Attorney Docket No.: ACHM/0002PC char combustion gases and the gasification gases.
- the seal can control a pressure balance between the gasification chamber 101 and the char combustion chamber 102, thereby preventing the combustion gases and the gasification gases from mixing with each other.
- the properties, e.g., lower heating value of the gasification gases may be maintained, reducing the amount of degradation of the gasification gases.
- a concentration of fluidizing medium may flow into the overflow chute108 from the gasification chamber 101 may be similar to a concentration of fluidizing medium that flows from the settling isolation chamber 107 into the gasification chamber.
- a mechanical delivery apparatus e.g., a conveyor line
- a reduction in the difficulty in handling high-temperature particles and/or fluidizing medium can occur.
- an increase in the amount of heat retention during the transport of the fluidizing medium from the char combustion chamber 102 and the gasification chamber 101 can occur, increasing efficiency of the system 100.
- the fuel source 110 may flow through the system 100 based on the fluidizing medium moving through the system 100.
- the residence time of the fuel source 110 in the gasification chamber may be controlled by the amount of fluidizing medium recirculation in the system 100.
- the amount of fluidizing recirculation may be controlled based on the air supply line 109 and/or the steam 111.
- the amount of fluidizing recirculation may be controlled based on the density of the fluidizing medium.
- the residence time may be controlled to allow for enhanced gasification of the fuel source 100 while maintaining suitable recirculation of the fluidizing medium to ensure consistent and/or uniform heat transfer from the fluidizing medium to the fuel source 110.
- FIG. 2 a system for reforming a biomass using a coaxially integrated gasification furnace is described. Biomass may be reformed using the coaxially integrated furnace as described above.
- product gas 112 emitted from the gasification cyclone separator 103 may proceed to a water scrubber, oil scrubber, and sulfur absorbing tower.
- the product gas 112 may then be transferred to a gas holder, in which the product gas 112 may be utilized for a gas engine or a flare stack.
- the product gas 112 may be transferred through a gas dryer and proceed to a gas compressor to be used in a micro gas turbine.
- the product gas 112 may be processed in a methanol synthesis reactor to produce methanol.
- the exhaust gas 113 emitted from the combustion cyclone separator 104 may proceed to a gas cooler, to produce an ash that may be removed from the furnace.
- Remaining exhaust gas 113 from the gas cooler may be processed in a super heater and air heater and filtered for residual particulates in the gas.
- Remaining nitrous oxide chemicals may be removed from the exhaust gas 113 and ejected via a smoke stack.
- the exhaust gas 113 may be recirculated to the system 100 to be used as a non-oxidizer gas, e.g., a pneumatic gas for recirculating fluidizing medium, thereby reducing manufacturing costs.
- Figure 3 is a schematic diagram illustrating a system for producing electrical power using a coaxially integrated gasification furnace, according to an embodiment of the disclosure. Electrical power may be produced using the one or more product gases 112 ejected from the gasification cyclone separators 103. In an embodiment, product gas 112 emitted from the gasification cyclone separator 103 may proceed to a scrubber and desulfurization facility.
- the product gas 112 may then be transferred to a gas holder, in which the product gas 112 may be utilized to produce electrical power using a micro gas turbine or gas engine. Alternatively, the product gas 112 may be processed in a methanol synthesis facility to produce methanol.
- PATENT Attorney Docket No.: ACHM/0002PC [0061]
- the exhaust gas 113 emitted from the combustion cyclone separator 104 may proceed to a gas cooler, to produce an ash that may be removed from the furnace. Remaining exhaust gas 113 from the gas cooler may be processed in a pre-heater and filtered for residual particulates in the exhaust gas 113.
- FIG. 4 is a schematic diagram illustrating a system for capturing carbon using a gasifier, according to an embodiment of the disclosure.
- the gasifier 401 emits product gas 112 from the gasification cyclone separators 103.
- product gas 112 emitted from the gasification cyclone separator 103 may proceed to a steam reformer 402.
- the steam reformer 402 produces a reformed gas 404 by removing sulfur, water, oil, or combinations thereof from the product gas 112.
- the steam reformer 402 allows for condensate 405 of the product gas 112 to be transferred to a steam boiler 406, via a steam return 407.
- the condensate 405 is then heated in the steam boiler 406 and may be re-introduced to the steam reformer 402 as steam 408.
- the reformed gas 404 may then be transferred to a CO2 stripping module 409.
- the CO 2 stripping module 409 removes CO 2 from the reformed gas 404 to product an H 2 rich gas 410 that may be extracted from the system.
- the stripped gas 411 has CO2 that is saturated with amines, which is transferred to an amine recovery module 412.
- the amine recovery module 412 removes one or more amines from the gas and reintroduces degassed amines 413 into the CO2 stripping module 409.
- FIG. 5 is a schematic diagram illustrating a gasifier system 500, according to an embodiment of the disclosure.
- an air supply 502 supplies one or more gases to the gasification chamber 101, the char combustion chamber 102, the settling isolation 105, and/or the overflow chute 108 via the air supply line 109.
- the air supply 502 can provide about 0.5 kg/hr to about 2,000 kg/hr of the one or more gases to the gasification chamber 101, the char combustion chamber 102, the settling isolation chamber 105, and/or the overflow chute 108, e.g., about 0.5 kg/hr to about 9.7 kg/hr, about 0.7 kg/hr to about 9.7 kg/hr, about 1.2 kg/hr to about 9.7 kg/hr, or about 9.0 kg/hr to about 9.7 kg/hr.
- one or more valves 504a-d may control the flow of the one or more gases to the gasification chamber 101, the combustion chamber 102, the overflow chute, and the settling isolation chamber 105, respectively.
- the one or more valves 504a-d can be opened and/or closed based on an input signal from a computing device 532.
- a computing device 532 can include one or more of a processor, a network interface, a display, or a combination thereof.
- a sensor (not shown) may be coupled to the one or more valves 504a-d to identify an amount of the one or more gases in the air supply line 109, in which the computing device 532 can transmit a signal to open and/or close the one or more valves 504a-d based on the sensor.
- a steam generator 506 supplies steam to the gasification chamber 101 and/or the settling isolation chamber 105 via a steam supply line 508.
- the steam generator 506 can provide a steam mass flow rate of about 0.05 kg/hr to about 2.0 kg/hr to the gasification chamber 101 and/or the settling isolation chamber 105, e.g., about 0.05 kg/hr to about 1.8 kg/hr, about 1.2 kg/hr to about 1.6 kg/hr, or about 1.3 kg/hr to about 1.5 kg/hr.
- the steam generator 506 can provide a steam volume flow rate of about 5 m 3 /hr to about 15 m 3 /hr to the gasification chamber 101 and/or the settling isolation chamber 105, e.g., about 5 m 3 /hr to about 12 m 3 /hr, about 8 m 3 /hr to about 12 PATENT Attorney Docket No.: ACHM/0002PC m 3 /hr, or about 11 m 3 /hr to about 12 m 3 /hr.
- the steam generator 506 can provide the steam at a pressure of about 1 atm to about 2.0 atm to the gasification chamber 101 and/or the settling isolation chamber 105, e.g., about 1.0 atm to about 1.8 atm, about 1.2 atm to about 1.7 atm, about 1.3 atm to about 1.6 atm, or about 1.4 atm to about 1.6 atm.
- the steam generator 506 can introduce the steam to the gasification chamber 101 and/or the settling isolation chamber 105 at a temperature of about 200 °C to about 1000 °C, e.g., about 200 °C, about 300 °C , about 400 °C , about 500 °C, about 600 °C, about 700 °C, about 800 °C, about 900 °C, or about 1000 °C.
- one or more valves 510a or 510b may control the flow of the one or more gases to the gasification chamber 101 or the settling isolation chamber 105, respectively.
- the one or more valves 510a or 510b can be opened and/or closed based on an input signal from a computing device 532, as described in the present disclosure.
- a sensor (not shown) may be coupled to the one or more valves 510a or 510b to identify an amount of the steam in the steam supply line 508, in which the computing device 532 can transmit a signal to open and/or close the one or more valves 510a or 510b based on the sensor.
- a supplemental gas 512 is introduced to the gasification chamber 101 via a supplemental supply line 514.
- the supplemental gas 512 can include one or more of a reactive carbon gas, e.g., alkanes, such as methane, ethane, propane, butane, pentane, hexane, heptane, octane, nonane, decane, or a combination thereof, alkenes, such as ethylene, propylene, butylene, pentylene, hexene, heptene, octene, nonene, decene, or a combination thereof, or alkylenes, such as ethyne, propyne, or the like, or nitrogen.
- the supplemental gas 512 can include propane.
- the one or more product gases 112 can be routed to the supplemental gas line 514 and introduced to the gasification chamber 101 as the supplemental gas 512 (not shown).
- PATENT Attorney Docket No.: ACHM/0002PC [0070]
- the supplemental gas 512 can be introduced at a mass flow rate of about 0.05 kg/hr to about 16,000 kg/hr to the gasification chamber 101, e.g., about 0.05 kg/hr to about 15,000 kg/hr, about 1.2 kg/hr to about 12,000 kg/hr, or about 1.3 kg/hr to about 10,000 kg/hr.
- the supplemental gas 512 can be introduced at a volume flow rate of about 5 m 3 /hr to about 6,000 m 3 /hr to the gasification chamber 101, e.g., about 5 m 3 /hr to about 5,000 m 3 /hr, about 8 m 3 /hr to about 4,000 m 3 /hr, or about 11 m 3 /hr to about 3,000 m 3 /hr.
- the supplemental gas 512 can be introduced at a pressure of about 1 atm to about 2.0 atm to the gasification chamber 101, e.g., about 1.0 atm to about 1.8 atm, about 1.2 atm to about 1.7 atm, about 1.3 atm to about 1.6 atm, or about 1.4 atm to about 1.6 atm.
- the supplemental gas 512 can be introduced to the gasification chamber 101 at a temperature of about 200 °C to about 1000 °C, e.g., about 200 °C, about 300 °C , about 400 °C , about 500 °C, about 600 °C, about 700 °C, about 800 °C, about 900 °C, or about 1000 °C.
- a valve 516 may control the flow of the supplemental gas 512 to the gasification chamber 101.
- the valve 516 can be opened and/or closed based on an input signal from a computing device 532, as described in the present disclosure.
- a sensor (not shown) may be coupled to the valve 516 to identify an amount of supplemental gas 512 being introduced to the gasification chamber 101, in which the computing device 532 can transmit a signal to open and/or close the valve 516 based on the sensor.
- an alternative supplemental gas can be introduced to gasification chamber 102. The alternative supplemental gas can modify and/or adjust a chemical reaction in the gasification chamber such that the product gas composition can be controlled.
- a sensor may be coupled to the alternative supplemental gas source to identify an amount of alternative supplemental gas being introduced to the gasification chamber 101, in which the computing device 532 can transmit a signal to open and/or close the valve based on the sensor.
- PATENT Attorney Docket No.: ACHM/0002PC [0073]
- a sensor 518 is coupled to the gasification chamber 101, in which the sensor 518 can identify one or more temperature of the gasification chamber 101 and/or the fluidizing medium.
- the valves 504a-d, 510a-b, or 516 can be opened and/or closed based on an input signal from a computing device 532, as described in the present disclosure, based on the sensor 518.
- the sensor 518 may indicate that a temperature of the gasification chamber 101 is about 700 °C, in which the computing device 532 may open one or more of valves 504a-d to introduce one or more gases from the air supply line 109 to reduce the temperature to about 650 °C.
- the sensor 518 can allow for enhanced control of the temperature of the gasification chamber 101 and/or the fluidizing medium.
- a sensor 520 is coupled to the gasification chamber 101, in which the sensor 520 can identify a volume of the fluidizing medium in the gasification chamber 101.
- valves 504a-d, 510a-b, or 516 can be opened and/or closed based on an input signal from a computing device 532, as described in the present disclosure, based on the sensor 520.
- a fluidizing medium 526 may be introduced to the char combustion chamber 102, in which the fluidizing medium 526 may overflow from the char combustion chamber 102 to the settling isolation chamber 105, and subsequently to the gasification chamber 101.
- the sensor 520 may indicate that a volume of fluidizing medium 526 in the gasification chamber 101 is about 0.005 m 3 , in which the computing device 532 may introduce additional fluidizing medium 526 via the char combustion chamber 102.
- the sensor 520 may indicate that a volume of fluidizing medium 526 in the gasification chamber 101 is about 0.006 m 3 , in which the computing device 532 may open one or more of valves 504a-d to pulse and/or flow additional air such that more fluidizing medium enters the char combustion chamber relative to the gasification chamber. Without being bound by theory, the sensor 520 can allow for enhanced control of the volume of fluidizing medium 526 in the gasification chamber 101.
- PATENT Attorney Docket No.: ACHM/0002PC [0075]
- a sensor 522 is coupled to the char combustion chamber 102, in which the sensor 522 can identify one or more temperature of the char combustion chamber 522 and/or the fluidizing medium.
- the valves 504a-d, 510a-b, or 516 can be opened and/or closed based on an input signal from a computing device 532, as described in the present disclosure, based on the sensor 522.
- the sensor 522 may indicate that a temperature of the char combustion chamber 102 is about 800 °C, in which the computing device 532 may open one or more of valves 510a or 510b to introduce steam from the steam supply line 508 to increase the temperature to about 850 °C.
- the sensor 522 can allow for enhanced control of the temperature of the char combustion chamber 102 and/or the fluidizing medium.
- a sensor 524 is coupled to the settling isolation chamber 105, in which the sensor 524 can identify a volume of the fluidizing medium in the settling isolation chamber 105.
- the valves 504a-d, 510a-b, or 516 can be opened and/or closed based on an input signal from a computing device 532, as described in the present disclosure, based on the sensor 524.
- a fluidizing medium 526 may be introduced to the char combustion chamber 102, in which the fluidizing medium 526 may overflow from the char combustion chamber 102 to the settling isolation chamber 105.
- the sensor 524 can allow for enhanced control of the volume of fluidizing medium 526 in the char combustion chamber 105.
- a sensor 525 is coupled to the settling isolation chamber 105, in which the sensor 525 can identify one or more temperature of the settling isolation chamber 105 and/or the fluidizing medium.
- the valves 504a-d, 510a-b, or 516 can be opened and/or closed based on an input signal from a computing device 532, as described in the present disclosure, based on the sensor 522.
- the senor 522 may indicate that a temperature of the settling isolation chamber 105 is about PATENT Attorney Docket No.: ACHM/0002PC 600 °C, in which the computing device 532 may open one or more of valves 510a or 510b to introduce steam from the steam supply line 508 to increase the temperature to about 650 °C.
- the sensor 525 can allow for enhanced control of the temperature of the settling isolation chamber 105 and/or the fluidizing medium.
- a sensor 528 is coupled to the exhaust gas 113, in which the sensor 528 analyzes the exhaust gas 113 to determine the presence of one or more oxygen species, e.g., carbon monoxide, carbon dioxide, nitrogen oxide, or a combination thereof.
- a valve 530 can be opened and/or closed based on an input signal from a computing device 532, as described in the present disclosure, based on the sensor 528. For example, the valve 530 can be opened to allow the exhaust gas 113 to be collected as product gas, when the exhaust gas 113 contains reduced and/or no oxygenated species.
- the valve 530 can be closed to prevent the exhaust gas 113 from being collected as product gas, when the exhaust gas 113 contains oxygenated species.
- the sensor 530 can allow for selective control exhaust gas collection, thereby increasing the overall yield of the system 500.
- the sensor 530 may have enhanced accuracy when the air supply line pulses the one or more gases into the gasification chamber 101, thereby allowing an air/fuel equivalence ratio to be monitored and the fluidizing medium to reach a target temperature before being transported to the gasification chamber.
- an analyzer (not shown) is coupled to the fuel source 110.
- the analyzer can include an elemental analyzer capable of analyzing one or more fuel sources using spectroscopy and/or spectrometry.
- the analyzer can include a laser abrasion spectroscopy instrument.
- the analyzer can include a mass spectrometer.
- the computing device 532 can receive a signal from the analyzer and transmit a signal to adjust one or more of the flow PATENT Attorney Docket No.: ACHM/0002PC rates of the one or more gases, steam, supplemental gases, or a combination thereof.
- FIG.6 is a flow diagram illustrating a gasifier system 600, according to an embodiment of the disclosure.
- a start routine is performed by a computing device 532 of a gasifier system 500.
- the start routine can include performing a safety check of one or more of the gasification chamber 101, char combustion chamber 102, settling isolation chamber 105, air supply 502, steam generator 506, valves 504a-d, valves 510a and 510b, valve 516, valve 530, or a combination thereof.
- the start routine can include performing an operational confirmation of one or more of the gasification chamber 101, char combustion chamber 102, settling isolation chamber 105, air supply 502, steam generator 506, valves 504a-d, valves 510a and 510b, valve 516, valve 530, sensor 518, sensor 520, sensor 522, sensor 524, sensor 528, or a combination thereof.
- the computing device 532 can transmit a signal to the gasification chamber 101, char combustion chamber 102, settling isolation chamber 105, air supply 502, steam generator 506, valves 504a-d, valves 510a and 510b, valve 516, valve 530, sensor 518, sensor 520, sensor 522, sensor 524, sensor 528, or a combination thereof, in which the computing device may confirm safety and/or operational viability by receiving a returning signal.
- the computing device 532 obtains a recipe.
- the computing device 532 can obtain the recipe by an input, e.g., user input via a display device.
- the recipe can include one or more operating parameters for each of the gasification chamber 101, char combustion chamber 102, settling isolation chamber 105, air supply 502, steam generator 506, valves 504a-d, valves 510a and 510b, valve 516, valve 530, sensor 518, sensor 520, sensor 522, sensor 524, sensor 528, or a combination thereof.
- the recipe PATENT Attorney Docket No.: ACHM/0002PC can include a gasification chamber temperature of 650, a char combustion chamber of 850, a settling isolation chamber temperature of 650 and a flow rate of about 0.5 kg/hr to about 10 kg/hr of the one or more gases from the air supply.
- one or more gases are introduced to the gasification chamber 101, the char combustion chamber 102 and/or the settling isolation chamber 105.
- the one or more gases can include one or more gases supplied from the air supply 502, via the air supply line 109.
- the air supply line 109 can provide about 0.5 kg/hr to about 10 kg/hr of the one or more gases, e.g., about 0.5 kg/hr to about 9.7 kg/hr, about 0.7 kg/hr to about 9.7 kg/hr, about 1.2 kg/hr to about 9.7 kg/hr, or about 9.0 kg/hr to about 9.7 kg/hr.
- the one or more gases can include a steam supplied from the steam generator 506, via the steam supply line 508.
- the steam generator 506 can provide a steam mass flow rate of about 0.05 kg/hr to about 2.0 kg/hr, e.g., about 0.05 kg/hr to about 1.8 kg/hr, about 1.2 kg/hr to about 1.6 kg/hr, or about 1.3 kg/hr to about 1.5 kg/hr.
- the steam generator 506 can provide a steam volume flow rate of about 5 m 3 /hr to about 15 m 3 /hr, e.g., about 5 m 3 /hr to about 12 m 3 /hr, about 8 m 3 /hr to about 12 m 3 /hr, or about 11 m 3 /hr to about 12 m 3 /hr.
- the one or more gases can include a supplemental gas 512 supplied via the supplemental supply line 514.
- the supplemental gas 512 can be introduced at a mass flow rate of about 0.05 kg/hr to about 800 kg/hr, e.g., about 0.05 kg/hr to about 700 kg/hr, about 1.2 kg/hr to about 600 kg/hr, or about 1.3 kg/hr to about 500 kg/hr.
- the supplemental gas 512 can be introduced at a volume flow rate of about 5 m 3 /hr to about 600 m 3 /hr, e.g., about 5 m 3 /hr to about 500 m 3 /hr, about 8 m 3 /hr to about 400 m 3 /hr, or about 11 m 3 /hr to about 300 m 3 /hr.
- the one or more gases can be introduced to the gasification chamber 101, the char combustion chamber 102 and/or the settling isolation chamber 105 when one or more of valves 504a-d, valves 510a and 510b, valve 516, valve 530 are in an open state.
- the steam may be introduced to the gasification chamber 101, the char combustion chamber 102, and/or the settling PATENT Attorney Docket No.: ACHM/0002PC isolation chamber 105 to increase the temperature of the gasifier system 100.
- the one or more gases may be restricted and/or prevented from entering the gasification chamber 101, the char combustion chamber 102 and/or the settling isolation chamber 105 when one or more of valves 504a-d, valves 510a and 510b, valve 516, valve 530 are in a closed state.
- a fuel source 110 is introduced to the gasification chamber 101.
- the fuel source 110 can be introduced to the gasification chamber 101 at a flow rate of about 2 kg/day to about 20 tons/day, e.g., about 2.1 kg/day to about 700 kg/day, about 10 kg/day to about 600 kg/day, or about 40 kg/day to about 50 kg/day.
- the fuel source 110 can be introduced to the gasification chamber 101 to provide a carbon content flow of about 1.0 kg/hr to about 100 kg/hr, e.g., about 1.0 kg/hr to about 3/0 kg/hr, about 1.5 kg/hr to about 2.5 kg/hr, or about 1.7 kg/hr to about 2.0 kg/hr.
- a product gas 112 is obtained from the gasification chamber 101 via the gasification cyclone separator 103.
- about 1.0 kg/hr to about 3.0 kg/hr of product gases 112 can be obtained from the gasification chamber 101 via the gasification cyclone separator 103, e.g., about 1.0 kg/hr to about 2.5 kg/hr, about 1.2 kg/hr to about 2.0 kg/hr, or about 1.4 kg/hr to about 1.6 kg/hr.
- about 0.1 Nm 3 /kW to about 0.3 Nm 3 /kW of the product gas 112 can be obtained from the gasification chamber 101 via the gasification cyclone separator 103, e.g., about 0.1 Nm 3 /kW to about 0.25 Nm 3 /kW, about 0.15 Nm 3 /kW to about 0.2 Nm 3 /kW, or about 0.17 Nm 3 /kW to about 0.19 Nm 3 /kW.
- about 1.0 Nm 3 /kg to about 5.0 Nm 3 /kg of the product gas 112 can be obtained from the gasification chamber 101 via the gasification cyclone separator 103, e.g., about 1.0 Nm 3 /kg to about 4.0 Nm 3 /kg, about 1.5 Nm 3 /kg to about 3.5 Nm 3 /kg, or about 2.0 Nm 3 /kg to about 2.2 Nm 3 /kg.
- FIG.7 is a flow diagram illustrating a method 700 of gasifying a fuel source, according to an embodiment of the disclosure.
- a fluidizing medium is heated in a gasification chamber 101, a char combustion chamber 102, and a settling isolation chamber 105.
- the fluidizing medium is heated to a temperature of about 500 °C to about 1000 °C, e.g., about 500 °C, about 600 °C, about 700 °C, about 800 °C, about 900 °C, about 1000 °C.
- the fluidizing medium is heated by introducing steam, from a steam generator 506, via a steam supply line 508.
- the steam can be introduced at a steam mass flow rate of about 0.05 kg/hr to about 2.0 kg/hr, e.g., about 0.05 kg/hr to about 1.8 kg/hr, about 1.2 kg/hr to about 1.6 kg/hr, or about 1.3 kg/hr to about 1.5 kg/hr.
- the steam generator 506 can provide a steam volume flow rate of about 5 m 3 /hr to about 15 m 3 /hr, e.g., about 5 m 3 /hr to about 12 m 3 /hr, about 8 m 3 /hr to about 12 m 3 /hr, or about 11 m 3 /hr to about 12 m 3 /hr.
- a fuel source 110 is injected to the gasification chamber 101.
- the fuel source 110 can be injected at a flow rate of about 2 kg/day to about 20 tons/day, e.g., about 2.1 kg/day to about 20 kg/day, about 10 kg/day to about 18 kg/day, or about 15 kg/day to about 20 kg/day.
- the fuel source 110 can be injected into the gasification chamber 101 to provide a carbon content flow of about 1.0 kg/hr to about 2.1 kg/hr, e.g., about 1.0 kg/hr to about 2.0 kg/hr, about 1.5 kg/hr to about 2.0 kg/hr, or about 1.7 kg/hr to about 2.0 kg/hr.
- the fuel source 110 can be introduced to the gasification chamber 101 via a plurality of airtight dispensers and/or feed stocks (not shown).
- a first fuel source can be introduced via a first airtight dispenser and/or feed stock, in which a second fuel source can be introduced via second airtight dispenser and/or feed stock.
- a plurality of feedstocks can allow for enhanced throughout of the gasifier system, thereby increasing the total amount of product gas.
- the steam from the heat source 106 and the fuel source 110 can be introduced at a ratio of about 0.5 to about 5.0 of steam to fuel source 110, e.g., about 0.5 to about 4.75, about 0.75 to about 3.5, or about 1.0 to about 1.5.
- the steam from the heat source 106 and the fuel source 110 can be introduced to provide a steam to carbon ratio of 1.0 to about 5.0, e.g., about 1.0 to about 4.8, about 1.2 to about 2.6, or about 1.4 to about 1.5.
- the fuel source 110 is gasified by contacting the fuel source 110 with the fluidizing medium in the gasification chamber 101.
- the fuel source can be gasified by heating the fuel source 110 with the fluidizing medium in the gasification chamber 101 to a temperature of about 500 °C to about 1000 °C, e.g., about 500 °C, about 600 °C, about 700 °C, about 800 °C, about 900 °C, about 1000 °C.
- the fuel source 110 can be heated by the fluidizing medium, pyrolyzed, and gasified in the gasification chamber 101.
- the fuel source 110 is carbonized in the gasification chamber 101.
- volatile components of the fuel sources injected into the gasification chamber 101 may be instantaneously gasified, and then solid carbon (char) may be gasified relatively slowly compared to the volatile components.
- the airtight dispenser may be equipped with dehydration means such as vacuum pump and/or super critical CO 2 .
- a product gas 112 is obtained from the gasification chamber 101.
- the product gas 112 is obtained from the gasification chamber 101 via the gasification cyclone separator 103.
- about 1.0 kg/hr to about 3.0 kg/hr of product gases 112 can be obtained from the gasification chamber 101 via the gasification cyclone separator 103, e.g., about 1.0 kg/hr to about 2.5 kg/hr, about 1.2 kg/hr to about 2.0 kg/hr, or about 1.4 kg/hr to about 1.6 kg/hr.
- about 0.1 Nm 3 /kW to about 0.3 Nm 3 /kW of the product gas 112 can be obtained from the gasification chamber PATENT Attorney Docket No.: ACHM/0002PC 101 via the gasification cyclone separator 103, e.g., about 0.1 Nm 3 /kW to about 0.25 Nm 3 /kW, about 0.15 Nm 3 /kW to about 0.2 Nm 3 /kW, or about 0.17 Nm 3 /kW to about 0.19 Nm 3 /kW.
- about 1.0 Nm 3 /kg to about 5.0 Nm 3 /kg of the product gas 112 can be obtained from the gasification chamber 101 via the gasification cyclone separator 103, e.g., about 1.0 Nm 3 /kg to about 4.0 Nm 3 /kg, about 1.5 Nm 3 /kg to about 3.5 Nm 3 /kg, or about 2.0 Nm 3 /kg to about 2.2 Nm 3 /kg.
- about 1.0 Nm 3 /kg to about 5.0 Nm 3 /kg of the product gas 112 can be obtained from the gasification chamber 101 via the gasification cyclone separator 103, e.g., about 1.0 Nm 3 /kg to about 4.0 Nm 3 /kg, about 1.5 Nm 3 /kg to about 3.5 Nm 3 /kg, or about 2.0 Nm 3 /kg to about 2.2 Nm 3 /kg [0092]
- a residual carbonized char and a portion of the fluidizing medium are directed to an overflow chute 108 of the gasification chamber 101.
- the overflow chute 108 is fluidly coupled to the char combustion chamber.
- directing the portion fluidizing medium to the overflow chute can provide a first seal between the gasification chamber 101 and the char combustion chamber 102.
- the first seal can control a pressure balance between the gasification chamber 101 and the char combustion chamber 102, thereby preventing the combustion gases and the gasification gases from mixing with each other.
- the properties, e.g., lower heating value of the gasification gases may be maintained, reducing the amount of degradation of the gasification gases.
- the char combustion chamber 102 can heat the residual carbonized char and the portion of the fluidizing medium to a temperature of about 500 °C to about 1000 °C using a heat source 106, the heat source 106 can emit heat via an electromagnetic wave such as microwave radiation, radio frequency radiation, infrared radiation, or ultraviolet radiation, inductive heating, and/or steam.
- an electromagnetic wave such as microwave radiation, radio frequency radiation, infrared radiation, or ultraviolet radiation, inductive heating, and/or steam.
- the heat source can introduce steam to the char combustion chamber 102 at a steam mass flow rate of about 0.05 kg/hr to about 1,200 kg/hr, e.g., about 0.05 kg/hr to about 1,100 kg/hr, about 1.2 kg/hr to about 1,000 kg/hr, or about 300 kg/hr to about 1,200 kg/hr.
- the heat source 106 can introduce steam to the char combustion chamber 102 at a steam volume flow rate of about 5 m 3 /hr to about 15 m 3 /hr, e.g., about 5 m 3 /hr to about 12 m 3 /hr, about 8 m 3 /hr to about 12 m 3 /hr, or about 11 m 3 /hr to about 12 m 3 /hr.
- an exhaust gas 113 is obtained from the char combustion chamber 102.
- the exhaust gases 113 can include carbon dioxide, nitrogen, nitrogen oxide, water, or a combination thereof.
- the exhaust gas 113 can be obtained by directing the exhaust gas 113 to a char combustion cyclone separator 104.
- the combustion cyclone separator 104 can emit about 1.0 kg/hr to about 3.0 kg/hr of exhaust gases 113, e.g., about 1.0 kg/hr to about 2.5 kg/hr, about 1.2 kg/hr to about 2.0 kg/hr, or about 1.4 kg/hr to about 1.6 kg/hr.
- the combustion cyclone separator 104 can emit about 1.0 kg/day to about 20 tons/day of exhaust gases 113, e.g., about 1.0 kg/day to about 18 tons/day, about 5.0 kg/day kg/hr to about 15 tons/day, or about 10 kg/day to about 10 tons/day.
- the portion of the fluidizing medium is collected in the settling isolation chamber 105.
- the fluidizing medium in the char combustion cyclone separator 104 may lose energy and fall down towards the settling isolation chamber 105, in which the fluidizing medium may build up in the settling isolation chamber 105.
- collecting the portion of the fluidizing medium in the settling isolation chamber can provide a second seal between the gasification chamber 101 and the char combustion chamber 102.
- the second seal can control a pressure balance between the gasification chamber 101 and the char combustion chamber 102, thereby preventing the combustion gases and the gasification gases from mixing with each other.
- the combustion gases and the PATENT Attorney Docket No.: ACHM/0002PC gasification gases from mixing the properties, e.g., lower heating value, of the gasification gases may be maintained, reducing the amount of degradation of the gasification gases.
- the portion of the fluidizing medium in the settling isolation chamber 105 is directed to the gasification chamber 101 by flowing one or more gases from an air supply line 109 to the settling isolation chamber 105 or the char combustion chamber 102.
- the one or more gases can be supplied from an air supply 502, via the air supply line 109.
- the air supply line 109 can provide about 0.5 kg/hr to about 10 kg/hr of the one or more gases, e.g., about 0.5 kg/hr to about 9.7 kg/hr, about 0.7 kg/hr to about 9.7 kg/hr, about 1.2 kg/hr to about 9.7 kg/hr, or about 9.0 kg/hr to about 9.7 kg/hr.
- Fluidizing medium size A first fluidizing medium having a first particle size of about 247 ⁇ m was simulated in the gasifier system 100 and a volume fraction was determined at each of 0.25 seconds (s), 0.5 s, 1 s, and 1.5 s. After 1.5 s the volume fraction in the settling isolation chamber 105 was reduced, while the volume fraction in the gasification chamber 101 increased, as shown in FIG. 12A. A second fluidizing medium having a second particle size of about 2470 ⁇ m was simulated in the gasifier system 100 and a volume fraction was determined at each of 0.25 seconds (s), 0.5 s, 1 s, and 1.5 s.
- a coaxially integrated gasification furnace including: a gasification chamber fluidly coupled to a gasification cyclone separator; a char combustion chamber fluidly coupled to a combustion cyclone separator, wherein the char combustion chamber is located within the gasification chamber; a settling isolation chamber having a first partition and a second partition, wherein the first partition separates the settling isolation chamber from PATENT Attorney Docket No.: ACHM/0002PC the combustion chamber, and the second partition separates the settling isolation chamber from the gasification chamber; and at least a temperature control element disposed on the settling isolation chamber.
- E2 The furnace of embodiment E1, wherein the char combustion chamber comprises a transparent wall configured to allow one or more electromagnetic waves of light to pass through the transparent wall.
- a gasification system including: a coaxially integrated gasification furnace, wherein the coaxially integrated gasification furnace comprises: a gasification chamber fluidly coupled to a gasification cyclone separator; a char combustion chamber fluidly coupled to a combustion cyclone separator, wherein the char combustion chamber is located within the gasification chamber; a settling isolation chamber having a first partition and a second partition, wherein the first partition separates the settling isolation chamber from the combustion chamber, and the second partition separates the settling isolation chamber from the gasification chamber; and at least a temperature control element disposed on the settling isolation chamber an air supply line fluidly coupled to the gasification chamber, the char combustion chamber, and the settling isolation chamber; a steam supply line fluidly coupled PATENT Attorney Docket No.: ACHM/0002PC to the gasification chamber, the char combustion chamber, and the settling isolation chamber; and one or more valves fluidly coupled to the air supply line or the steam supply line.
- a coaxially integrated gasification furnace comprises: a gas
- E8 The system of embodiment E7, wherein the char combustion chamber comprises a transparent wall configured to allow one or more electromagnetic waves of light to pass through the transparent wall.
- E9. The system of embodiment E8, wherein the transparent wall comprises quartz.
- E10. The system of embodiment E8 or E9, further comprising a supplemental gas line coupled to the gasification chamber, wherein the supplemental gas line comprises a supplemental gas comprising propane.
- E11 The system of any one of embodiments E7-E10, wherein the steam supply line is fluidly coupled to the gasification chamber and the settling isolation chamber of the coaxially integrated gasification furnace.
- a method of gasifying a fuel source comprising: heating a fluidizing medium in a gasification chamber, a char combustion chamber, and a settling isolation chamber of a gasification system to a temperature of about 500 °C to about 1000 °C by introducing a steam; injecting a fuel source to the gasification chamber; gasifying the fuel source by contacting the fuel source with the fluidizing medium in the gasification PATENT Attorney Docket No.: ACHM/0002PC chamber; obtaining a product gas from the gasification chamber; directing a residual carbonized char and a portion of the fluidizing medium to an overflow chute of the gasification chamber, the overflow chute fluidly coupled to the char combustion chamber; heating the residual carbonized char and at least a portion of the fluidizing medium in the char combustion chamber; obtaining an exhaust gas from the char combustion chamber; collecting the portion of the fluidizing medium in the settling isolation chamber; and directing the portion of the fluidizing medium in the settling isolation chamber to the gasification chamber by flowing one or more
- E15 The method of embodiment E14, wherein directing the portion fluidizing medium to the overflow chute further comprises providing a first seal between the gasification chamber and the char combustion chamber.
- E16 The method of embodiment E14 or E15, wherein collecting the portion of the fluidizing medium in the settling isolation chamber comprises providing a second seal between the gasification chamber and the char combustion chamber.
- E17 The method of any one of embodiments E14-E16, wherein obtaining the exhaust gas further comprises directing the exhaust gas to a char combustion cyclone separator. [0122] E18.
- the present disclosure is directed to a coaxially integrated gasification system that provides increased efficiency compared to conventional gasification systems.
- the gasification system can reduce operating expenses by limiting the use of manual fluidizing movement due to the coaxial arrangement.
- the gasification system can gasify a plurality of fuel sources, including coal, biomass, and/or municipal waste.
- the system can provide enhanced recovery of energy from gasifying fuel sources when compared to conventional gasification systems.
- the coaxially integrated gasification system can provide a controllable gasifier system with an ability to independently control one or more of the fluidizing temperature, infrared emission, steam temperature, steam flow rate, air temperature, air flow rate, combustion temperature, gasification temperature, pneumatic flow rates, additives, or a combination thereof by implementing one or more sensors in the system.
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Abstract
A coaxially integrated gasification furnace is described. The coaxially integrated gasification furnace includes a gasification chamber fluidly connected to a gasification cyclone separator. The coaxially integrated gasification system also includes a char combustion chamber fluidly connected to a combustion cyclone separator, in which the char combustion chamber is located within the gasification chamber. A settling char combustion chamber is located near the char combustion chamber and is separated by a first partition and a second partition from the gasification chamber and the combustion chamber. At least a temperature control element is disposed on the settling isolation chamber.
Description
ACHM/0002PC COAXIALLY STACKED COAXIAL FUEL GASIFIER CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims priority to U.S. Provisional Patent Application No. 63/449,225, filed March 1, 2023, and U.S. Provisional Patent Application No.63/455, 735, filed March 30, 2023, each of which are incorporated herein by reference in their entirety. BACKGROUND Field [0002] Embodiments of the present disclosure generally relate to a gasification system for gasifying various feedstocks. Description of the Related Art [0003] Numerous efforts are being made to produce highly efficient power generation systems which employ fossil fuel, waste material and other biomasses as fuel. One such technology being employed is an integrated gasification combined cycle (IGCC), which converts coal or biomass into clean chemical energy by gasification. Conventional IGCC systems include twin tower circulation type gasification furnaces or two-bed pyrolysis reactor systems having two furnaces, e.g., a gasification furnace and a char combustion furnace. These systems often include a fluidizing medium and char that is circulated between the gasification furnace and the char combustion furnace. Unfortunately, these systems are challenging to economically down size due to the cost associated with the handling of high-temperature particles, such as net thermal efficiencies, waste heat management, obtaining a sufficient amount of particle circulation between the gasification furnace and the char combustion furnace, controlling of the circulating amount of particles, and stable operation, and problems relating to operation, such as a failure in temperature control of the char combustion furnace independently of other operations. Additionally, economical sizing of commercial reactors to a size capable of being transported reduces the overall amount of energy capable of being produced.
PATENT Attorney Docket No.: ACHM/0002PC [0004] Other attempts to improve efficiency have focused on integrating a gasification furnace with a single fluidized-bed furnace that has a gasification chamber, a char combustion chamber, and a low-temperature combustion chamber divided by partitions. Unfortunately, the chambers are adjacent to one another in a linear fashion, in which the linear orientation of the integrated gasification furnace does not allow efficient use of the heat generated by the combustion furnace due to the unutilized hot surfaces normally covered by thermal insulators. As such, these linear integrated gasification furnaces suffer from reduced efficiency as the heat being produced is not maximized. [0005] Accordingly, a highly efficient power generation system that can employ a wide range of fuels, e.g., coal, biomass, municipal waste, or the like, is needed. SUMMARY [0006] In an embodiment, the present disclosure is directed to a coaxially integrated gasification furnace. The coaxially integrated gasification furnace includes a gasification chamber fluidly connected to a gasification cyclone separator. The coaxially integrated gasification furnace also includes a char combustion chamber fluidly connected to a combustion cyclone separator, in which the char combustion chamber is located within the gasification chamber, and/or positioned coaxially therewith. A settling isolation chamber is located near the char combustion chamber and is separated by a first partition and a second partition from the gasification chamber and the combustion chamber. At least a temperature control element is disposed on the settling char combustion chamber. [0007] In an embodiment, the present disclosure is directed to a gasification system. The gasification system includes a coaxially integrated gasification furnace fluidly coupled to an air supply line and a steam supply line. One or more valves couple each of the air supply line and the steam supply line to the coaxially integrated gasification furnace. The coaxially integrated gasification
PATENT Attorney Docket No.: ACHM/0002PC furnace includes a gasification chamber fluidly coupled to a gasification cyclone separator. A char combustion chamber is fluidly coupled to a combustion cyclone separator. The char combustion chamber is located within the gasification chamber. The gasification furnace includes a settling isolation chamber having a first partition and a second partition. The first partition separates the settling isolation chamber from the combustion chamber, and the second partition separates the settling isolation chamber from the gasification chamber. The gasification furnace includes at least a temperature control element disposed on the settling isolation chamber. [0008] In an embodiment, the present disclosure is directed to a method of gasifying fuel sources. The method includes heating a fluidizing medium in a gasification chamber, a char combustion chamber, and a settling isolation chamber of a gasification system to a temperature of about 500 °C to about 1000 °C by introducing a steam. A fuel source is injected to the gasification chamber. The fuel source is gasified by contacting the fuel source with the fluidizing medium in the gasification chamber. A product gas is obtained from the gasification chamber. A residual carbonized char and a portion of the fluidizing medium are directed to an overflow chute of the gasification chamber. The overflow chute is fluidly coupled to the char combustion chamber. The residual carbonized char and the portion of the fluidizing medium are heated in the char combustion chamber. An exhaust gas is obtained from the char combustion chamber. The portion of the fluidizing medium is collected in the settling isolation chamber. The portion of the fluidizing medium in the settling isolation chamber is directed to the gasification chamber by flowing one or more gases from an air supply line to the settling isolation chamber or the char combustion chamber. BRIEF DESCRIPTION OF THE DRAWINGS [0009] So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to
PATENT Attorney Docket No.: ACHM/0002PC embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only exemplary embodiments and are therefore not to be considered limiting of its scope, may admit to other equally effective embodiments. [0010] Figure 1 is a schematic diagram illustrating a coaxially integrated gasification furnace, according to at least an embodiment of the disclosure. [0011] Figure 2 is a schematic diagram illustrating a system for reforming a fuel source using a coaxially integrated gasification furnace, according to at least an embodiment of the disclosure. [0012] Figure 3 is a schematic diagram illustrating a system for producing electrical power using a coaxially integrated gasification furnace, according to at least an embodiment of the disclosure. [0013] Figure 4 is a schematic diagram illustrating a system for capturing carbon using a gasifier, according to at least an embodiment of the disclosure. [0014] Figure 5 is a schematic diagram illustrating a gasification system, according to at least an embodiment of the disclosure. [0015] Figure 6 is a flow diagram illustrating a method of operating a gasification system, according to at least an embodiment of the disclosure. [0016] Figure 7 is a flow diagram illustrating a method of gasifying a fuel source, according to at least an embodiment of the disclosure. [0017] Figures 8A and 8B are graphs illustrating an energy consumption and/or lower heating value (LHV) relative to temperature, according to at least one embodiment of the disclosure. Figure 8A is a graph illustrating an energy consumption relative to temperature. Figure 8B is a graph illustrating an LHV relative to temperature.
PATENT Attorney Docket No.: ACHM/0002PC [0018] Figure 9 is a graph illustrating an LHV relative to varying steam to fuel source ratios, according to at least one embodiment of the disclosure. [0019] Figure 10 is a graph illustrating varying concentrations of a product gas composition, according to at least one embodiment of the disclosure. [0020] Figures 11A and 11B are graphs illustrating gasifier system efficiency, according to at least an embodiment of the disclosure. Figure 10A is a graph illustrating a cold gas efficiency. Figure 10B is a graph illustrating a hot gas efficiency. [0021] Figures 12A and 12B are diagram illustrating a fluidizing medium particle size efficiency, according to at least an embodiment of the disclosure. Figure 12A is a diagram illustrating a first fluidizing medium particle size. Figure 12B is a diagram illustrating a second fluidizing medium particle size. [0022] To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements and features of one embodiment may be beneficially incorporated in other embodiments without further recitation. DETAILED DESCRIPTION [0023] The present disclosure is directed to a coaxially integrated gasification system that is profitable in gasifying and combusting fuels such as coal, biomass, and municipal waste. The system comprises a highly efficient system that can recover energy from gasifying fuel sources. [0024] FIG. 1 schematically shows the basic structure of a coaxially integrated gasification furnace 100. A coaxially integrated gasification furnace including a gasification chamber 101, a combustion chamber 102, a gasification cyclone separator 103, and a char combustion cyclone separator 104 for performing three respective functions including: pyrolysis and/or steam reforming due to the presence of steam and absence of oxygen due to the
PATENT Attorney Docket No.: ACHM/0002PC coaxial arrangement of the gasification chamber and the char combustion chamber , char combustion, and product recovery. [0025] The gasification chamber 101 and the combustion chamber 102 are housed coaxially in a furnace such that the gasification chamber 101 is located outside of coaxial arrangement below and/or concentric with the combustion chamber 102. The gasification chamber 102 includes a fluidized bed positioned in a coaxially outer region, which contains a of fluidizing medium (e.g., an abrasion resistant material such as sand such as silica sand or refractory sand, e.g., olivine or molochite). In some embodiments, the fluidizing medium can include one or more catalytically active elements capable of absorbing one or more infrared wavelengths of light. For example, the fluidizing medium may include an element capable of absorbing an infrared wavelength of light such that the fluidizing medium absorbs thermal energy when flowing through the system 100. [0026] In some embodiments, the gasification chamber 102 can include about 5 kg to about 8 kg of the fluidizing medium, e.g., about 5 kg to about 7 kg, about 5.5 kg to about 6.8 kg, or about 6.4 kg to about 6.7 kg. In some embodiments, the fluidizing medium can fill a volume of about 0.001 m3 to about 0.01 m3 of the gasification chamber 102, e.g., about 0.001 m3 to about 0.009 m3, about 0.002 m3 to about 0.006 m3, or about 0.005 m3 to about 0.006 m3. In some embodiments, the fluidizing medium can include a particle size of about 100 μm to about 5000 μm, e.g., about 100 μm to about 4000 μm, about 250 μm to about 2500 μm, about 100 μm to about 500 μm, or about 2000 μm to about 3000 μm. In some embodiments, the fluidizing medium can include a density of about 1000 kg/m3 to about 2000 kg/m3, e.g., about 1000 kg/m3 to about 1800 kg/m3, about 1100 kg/m3 to about 1600 kg/m3, about 1150 kg/m3 to about 1500 kg/m3, or about 1200 kg/m3 to about 1300 kg/m3. [0027] In some embodiments, fluidized medium adds catalytic reaction and/or supplemental heat generation. The fluidized medium may produce a gas, a light combustible, a heavy combustible, and a heavy incombustible (e.g.,
PATENT Attorney Docket No.: ACHM/0002PC metals) as a result of a fuel source, described below. The light combustible may have a specific gravity that is less than the specific gravity of the fluidizing medium, in which the light combustible may rise to the top of the fluidized bed. The light combustible may then fall through the overflow chute, described below. The heavy combustible and heavy incombustible may remain at the bottom of the fluidized bed. The heavy combustible and heavy incombustible may be retrieved from a lower collection site of the gasification chamber. [0028] The fluidizing medium is held in a fluidizing state by the fluidizing gas, and a splash zone, positioned coaxially above the dense bed, which contains both the fluidizing medium and a large amount of gases, with the fluidizing medium splashing violently. Above the fluidized bed (e.g., above the splash zone), there is a gasification cyclone separator 103 which contains almost no fluidizing medium, but is primarily made up of gases, e.g., product gases and/or gasification gases such as carbon monoxide, carbon dioxide, methane, alkanes, alkenes, alkylenes, nitrogen, sulfur, and a combination thereof. [0029] Gas emitted from the fluidizing bed flows toward the gasification cyclone separator 103. The gasification cyclone separator 103 separates one or more gases from one or more particles, e.g., sand such as silica sand or refractory sand, e.g., olivine or molochite. For example, a cyclone separator may separate one or more particulates, e.g., sand such as silica sand or refractory sand, e.g., olivine or molochite, from a gas as a result of inertia. The gasification gas enters the gasification cyclone separator 103, in which a spiral vortex is formed due to the tangentially ejecting gas mixture port and conical shape of the cyclone separator. Lighter components and gas, e.g., carbon monoxide, carbon dioxide, methane, alkanes, alkenes, alkylenes, nitrogen, sulfur, and a combination thereof, continue to flow and exit the cyclone separator as product gas 112, in which heavier components, e.g., sand such as silica sand or refractory sand, e.g., olivine or molochite, fall back towards the fluidized bed of the gasification chamber as a result of inertia loss. Without being bound by theory, the fluidizing medium may absorb one or more infrared
PATENT Attorney Docket No.: ACHM/0002PC wavelengths of light while falling back towards the fluidized bed, such that the fluidizing medium may activate the fuel source immediately upon contact in the gasification chamber. [0030] In an embodiment, the product gas 112 comprises one or more volatile organic compounds (VOCs). The VOCs can include an oxygen-free VOC and/or an oxygenated VOC. For example, an oxygen-free gas can include a gas which does not contain any oxygen, e.g., alkanes, such as methane, ethane, propane, butane, pentane, hexane, heptane, octane, nonane, decane, or a combination thereof, alkenes, such as ethylene, propylene, butylene, pentylene, hexene, heptene, octene, nonene, decene, or a combination thereof, or alkylenes, such as ethyne, propyne, or the like, or nitrogen. As a further example, an oxygenated VOC can include carbon monoxide, carbon dioxide, diatomic oxygen, nitrogen oxide, water vapor (steam), or a combination thereof. [0031] In some embodiments, the product gas 112 can include a lower heating value (LHV), e.g., net calorific value, expressed in Mega-Joules (MJ) per normal cubic meter of gas (Nm3), of about 5 MJ/Nm3 to about 30 MJ/Nm3, e.g., about 5 MJ/Nm3 to about 25 MJ/Nm3, about 10 MJ/Nm3 to about 20 MJ/Nm3, or about 15 MJ/Nm3 to about 19.5 MJ/Nm3. [0032] In some embodiments, the gasification cyclone separator 103 can emit about 1.0 kg/hr to about 2,000 kg/hr of product gases 112, e.g., about 1.0 kg/hr to about 2,000 kg/hr, about 1.2 kg/hr to about 1,500 kg/hr, or about 1.4 kg/hr to about 1,000 kg/hr. In some embodiments, about 0.1 Nm3/kW to about 0.3 Nm3/kW of the product gas can be emitted by the gasification cyclone separator 103, e.g., about 0.1 Nm3/kW to about 0.25 Nm3/kW, about 0.15 Nm3/kW to about 0.2 Nm3/kW, or about 0.17 Nm3/kW to about 0.19 Nm3/kW. In some embodiments, about 1.0 Nm3/kg to about 5.0 Nm3/kg of the product gas can be emitted by the gasification cyclone separator 103, e.g., about 1.0 Nm3/kg to about 4.0 Nm3/kg, about 1.5 Nm3/kg to about 3.5 Nm3/kg, or about 2.0 Nm3/kg to about 2.2 Nm3/kg. In some embodiments, about 1.0 Nm3/kg to about
PATENT Attorney Docket No.: ACHM/0002PC 5.0 Nm3/kg of the product gas can be emitted by the gasification cyclone separator 103, e.g., about 1.0 Nm3/kg to about 4.0 Nm3/kg, about 1.5 Nm3/kg to about 3.5 Nm3/kg, or about 2.0 Nm3/kg to about 2.2 Nm3/kg. [0033] The char combustion chamber 102 is located within the gasification chamber 101, in which the char combustion chamber 102 extends downward coaxially from the furnace ceiling. The char combustion chamber 102 may be a cylinder or conically shaped reservoir that extends from the ceiling of the furnace. In an embodiment, the combustion chamber 102 may be located inside the gasification chamber 101, in which a portion of the combustion chamber 102 is located within the fluidizing bed of the gasification chamber 101. The gasification chamber 101 and the char combustion chamber 102, are divided by walls such that each chamber does not interact with one another. In some embodiments, a wall of the char combustion chamber can include a transparent wall, e.g., a wall that may allow one or more infrared wavelengths of light to pass through. For example, the transparent wall can include quartz, alumina, silicon, silicon carbide, diamond, or any other suitable material that allows infrared and/or thermal energy to transmit through the char combustion chamber wall. Without being bound by theory, a transparent wall may allow for the fluidizing medium to absorb heat while flowing throughout the char combustion chamber. In some embodiments, the char combustion wall may include a hardness and/or abrasion resistance to prevent the fluidizing media from degrading the char combustion wall. [0034] As such the combustion chamber 101 and gasification chamber 102 do not mix gases. Additionally, or alternatively, the combustion chamber 102 that is located within the bed of the gasification chamber 101 allows for heat generated by the char combustion chamber 102 to be fully utilized by the gasification chamber 101, promoting enhanced efficiency for gasification. [0035] A combustion cyclone separator 104 is located directly above the combustion chamber 102. The combustion cyclone separator 104 separates one or more gases from one or more particles existing in the combustion
PATENT Attorney Docket No.: ACHM/0002PC chamber, as described above. The combustion cyclone separator 104 may separate one or more particulates, e.g., sand such as silica sand or refractory sand, e.g., olivine or molochite, from exhaust gases 113 emitted from the combustion chamber 102. Particulates, e.g., sand such as silica sand or refractory sand, e.g., olivine or molochite, will fall from the combustion cyclone separator 104 towards a settling isolation chamber 105 disposed near a portion of the char combustion chamber 102 which is in contact with the gasification chamber 101. The settling isolation chamber 105 separates the combustion chamber 102 from the gasification chamber 101. [0036] In some embodiments, the exhaust gases 113 can include carbon dioxide, nitrogen, nitrogen oxide, water, or a combination thereof. In some embodiments, the exhaust gases 113 can include a temperature of about 800 °C to about 1100 °C, e.g., about 800 °C to about 1000 °C, about 950 °C to about 950 °C, or about 900 °C to about 950 °C. In some embodiments, the combustion cyclone separator 104 can emit about 1.0 kg/hr to about 3.0 kg/hr of exhaust gases 113, e.g., about 1.0 kg/hr to about 2.5 kg/hr, about 1.2 kg/hr to about 2.0 kg/hr, or about 1.4 kg/hr to about 1.6 kg/hr. In some embodiments, the combustion cyclone separator 104 can emit about 1.0 kg/day to about 20 tons/day of exhaust gases 113, e.g., about 1.0 kg/day to about 18 tons/day, about 5.0 kg/day kg/hr to about 15 tons/day, or about 10 kg/day to about 10 tons/day. [0037] In some embodiments, the gasification chamber 101, the char combustion chamber 102, the gasification cyclone separator 103 and the combustion cyclone separator 104, are disposed in one fluidized-bed furnace, with the char combustion chamber 102 being located above the gasification chamber 101, the gasification cyclone separator 103 and the combustion cyclone separator 104 being positioned above the char combustion chamber 102. [0038] The settling isolation chamber 105 acts to settle fluidizing medium. The settling isolation chamber 105 includes a settled fluidized bed such that a
PATENT Attorney Docket No.: ACHM/0002PC “U trap” is be formed to prevent one or more combustion gases from entering the gasification chamber 101 and/or one or more gasification gases from entering the combustion chamber 102. The settling isolation chamber 105 may include a section of the combustion chamber 102 which is in contact with the gasification chamber 101 as a function of the buildup of the fluidized medium overflowing and falling into the gasification chamber 101. As such, the char combustion chamber 102 is separated into the settling isolation chamber 105 and another portion of the char combustion chamber, the main char combustion chamber. The settling isolation chamber 105 is divided from the main char combustion chamber by a partition wall. The settling isolation chamber 105 and the gasification chamber 101 are divided from each other by a second partition wall, which prevents gases from entering the combustion chamber. [0039] The char combustion chamber 102 may be operated at a temperature range of about 500 °C to about 1000 °C, e.g., about 500 °C, about 600 °C, about 700 °C, about 800 °C, about 900 °C, about 1000 °C. In an embodiment, the char combustion chamber 102 may be operated at a temperature of about 850 °C. The gasification chamber 101 may be operated at a temperature range of about 500 °C to about 1000 °C, e.g., about 500 °C, about 600 °C, about 700 °C, about 800 °C, about 900 °C, about 1000 °C. In an embodiment, the gasification chamber 101 may be operated at a temperature of about 650 °C. The char combustion chamber 102 may be operated at a pressure range of about 0.5 atm to about 10 atm, e.g., about 0.5 atm to about 10 atm, about 1 atm to about 8 atm, about 1 atm to about 5 atm, or about 1.5 atm to about 2.0 atm. In an embodiment, the char combustion chamber 102 may be operated at a pressure of about 1.5 atm. The gasification chamber 101 may be operated at a pressure range of 0.5 atm to about 10 atm, e.g., about 0.5 atm to about 10 atm, about 1 atm to about 8 atm, about 1 atm to about 5 atm, or about 1.5 atm to about 2.0 atm. In an embodiment, the gasification chamber 101 may be operated at a temperature of about 1.0 atm.
PATENT Attorney Docket No.: ACHM/0002PC [0040] The char combustion chamber 102 is heated by a heat source 106. While FIG.1 shows the heat source 106 in the char combustion chamber, the heat source 106 may also introduce heat and/or steam to the gasification chamber 101 (not shown). The heat source 106 may include any steam or heat exchanger mechanism as described in the present disclosure, e.g., microwave radiation or inductive heating. The steam may be introduced to the gasification chamber 101 or the char combustion chamber 102 via the heat source 106 at a steam mass flow rate of about 0.05 kg/hr to about 1,200 kg/hr, e.g., about 0.05 kg/hr to about 1,100 kg/hr, about 1.2 kg/hr to about 1,000 kg/hr, or about 300 kg/hr to about 1,200 kg/hr. The steam may be introduced to the gasification chamber 101 or the char combustion chamber 102 via the heat source 106 at a steam volume flow rate of about 5 m3/hr to about 15 m3/hr, e.g., about 5 m3/hr to about 12 m3/hr, about 8 m3/hr to about 12 m3/hr, or about 11 m3/hr to about 12 m3/hr. [0041] The steam may be introduced at a pressure of about 1 atm to about 2.0 atm, e.g., about 1.0 atm to about 1.8 atm, about 1.2 atm to about 1.7 atm, about 1.3 atm to about 1.6 atm, or about 1.4 atm to about 1.6 atm. The steam can be introduced at a temperature of about 200 °C to about 1000 °C, e.g., about 200 °C, about 300 °C , about 400 °C , about 500 °C, about 600 °C, about 700 °C, about 800 °C, about 900 °C, or about 1000 °C. In some embodiments, the steam can include an enthalpy of about 5000 KJ to about 9000 KJ, e.g., about 5000 KJ to about 8000 KJ, about 6000 KJ to about 7800 KJ, or about 7000 KJ to about 7780 KJ. [0042] In some embodiments, the steam temperature introduced via the heat source 106 controls the temperature of the char combustion chamber 102 and/or the gasification chamber 101. For example, the heat source 106 introduces steam to the char combustion chamber 102 to operate the char combustion chamber 102 at a temperature of about 850 °C. As a further example, the heat source 106 introduces steam to the gasification chamber 101 to operate the gasification chamber 101 at a temperature of about 650 °C. In
PATENT Attorney Docket No.: ACHM/0002PC some embodiments, the heat source 106 may heat the fluidizing medium of the gasification chamber 101 such that the fluidizing medium has a temperature of about 650 °C to about 1000 °C, e.g., about 700 °C to about 900 °C, about 750 °C to about 850 °C, or about 800 °C to about 850 °C. In some embodiments, the heat source 106 may heat the fluidizing medium of the gasification chamber 101 such that the fluidizing medium has a thermal energy of about 4000 KJ to about 6000 KJ, e.g., about 4000 KJ to about 5500KJ, about 4500 KJ to about 5200 KJ, or about 5000 KJ to about 5100 KJ. [0043] In some embodiments, the fluidizing medium that has been heated in the char combustion chamber 102 flows into the combustion cyclone separator 104 and falls into the settling isolation chamber 105. The fluid medium can build up in the settling isolation chamber 105 and over flow into the gasification chamber 101. [0044] In some embodiments, the settling isolation chamber 106 includes temperature control elements 107. The temperature control elements 107 may heat or cool the temperature of the fluidized medium and/or the gasification chamber to maintain a temperature of about 200 °C to about 850 °C, e.g., about 200 °C to about 800 °C, about 250 °C to about 700 °C, or about 250 °C to about 650 °C. The temperature control elements 107 may include a source of heating, e.g., steam, microwave radiation, inductive heating, or a combination thereof. For example, the temperature control elements 107 may include iron containing particles heated by inductively coupled radio frequency (RF). As a further example, the Fe containing particles may be heated by microwave, induction heating, infrared, resistive heating, or the like. An overflow chute 108 exists within the gasification chamber 101. As a further example, the temperature control elements 107 can include introducing steam at a pressure of about 1.0 atm to about 2.0 atm, a temperature of about 200 °C to about 850 °C, and a mass flow rate of about 1.0 kg/hr to about 2.0 kg/hr. [0045] An overflow chute 108 exists within the gasification chamber 101. The overflow chute 108 is a channel located in the fluidized bed of the
PATENT Attorney Docket No.: ACHM/0002PC gasification chamber 101. The overflow chute 108 extends upwardly from the fluidized bed of the gasification chamber 101 upwards towards the splash zone. The channel has an orifice located above the fluidized bed of the gasification chamber 101. The orifice allows fluidized medium that is falling from the settling isolation chamber 105 to enter the channel. [0046] The overflow chute extends through the fluidized bed towards the char combustion chamber 102, such that the particulates are transported back towards an air supply line 109 of the char combustion chamber 102. The air supply line 109 provides one or more gases, e.g., air or inert gases such as argon, helium, nitrogen, or a combination thereof. The air supply line 109 can provide about 0.5 kg/hr to about 2,000 kg/hr of the one or more gases, e.g., about 0.5 kg/hr to about 9.7 kg/hr, about 0.7 kg/hr to about 9.7 kg/hr, about 1.2 kg/hr to about 9.7 kg/hr, or about 9.0 kg/hr to about 9.7 kg/hr. While the air supply line 109 is shown to introduce one or more gases to the char combustion chamber 102, the air supply line 109 may supply one or more gases to any of the components of the system 100, e.g., the gasification chamber 101, the char combustion chamber 102, the temperature control element 107, the settling isolation chamber 105, the heat source 106, and/or the fuel source 110. [0047] In some embodiments, the air supply line 109 provides the one or more gases to inject additional fluidized medium into the combustion chamber 102, thereby providing a recirculation of the fluidized medium in the system 100. Without being bound by theory, the air supply line 109 can allow for an enhanced control of the flow of fluidizing medium between the gasification chamber 101 and the char combustion chamber 102. In some embodiments, the air supply line 109 can provide the recirculation of the fluidized medium in the system 100 by pulsing one or more of the gases at a pulse rate of 0.1 s to about 30 s, e.g., about 0.1 s to about 25 s, about 1 s to about 20 s, about 5 s to about 15 s, or about 8 s to about 10 s. Without being bound by theory, the air supply line 109 can provide one or more gases as either an oxidizer gas or a pneumatic transportation, thereby providing control of combustion
PATENT Attorney Docket No.: ACHM/0002PC stoichiometry to promote either greater combustion and/or movement of the fluidizing medium. [0048] In some embodiments, fluidized medium may build up in the channel of the overflow chute 108 to prevent gasification gas from traveling through the overflow chute 108 and into the combustion chamber 102. Thus, the gasification chamber 101 and the char combustion chamber 102 are divided from each other by the partition walls such that no gases flow there between. [0049] A fuel source 110, e.g., coal, waste, biomass, or the like is injected into the gasification chamber 101 via an airtight dispenser and/or feed stock. The fuel source can include one or more polymers, e.g., polyethylene, polypropylene, polystyrene, or a combination thereof. In some embodiments, the fuel source 110 can include an LHV, e.g., a net calorific value, of about 50,000 KJ to about 200,000 KJ, e.g., about 50,000 KJ to about 180,000 KJ, about 80,000 KJ to about 150,000 KJ, or about 90,000 KJ to about 100,000 KJ. In some embodiments, the fuel source can be injected to provide a hydrogen content of about 0.1 kg/hr to about 0.5 kg/hr, e.g., about 0.1 kg/hr to about 0.4 kg/hr, about 0.2 kg/hr to about 0.4 kg/hr, or about 0.2 kg/hr to about 0.3 kg/hr. [0050] In some embodiments, the fuel source 110 can be injected at a flow rate of about 2 kg/day to about 20 kg/day, e.g., about 2.1 kg/day to about 20 tons/day, about 10 kg/day to about 18 kg/day, or about 15 kg/day to about 20 kg/day. In some embodiments, the fuel source 110 can be injected into the gasification chamber 101 to provide a carbon content flow of about 1.0 kg/hr to about 2.1 kg/hr, e.g., about 1.0 kg/hr to about 2.0 kg/hr, about 1.5 kg/hr to about 2.0 kg/hr, or about 1.7 kg/hr to about 2.0 kg/hr. [0051] In some embodiments, the fuel source 110 can be introduced to the gasification chamber 101 via a plurality of airtight dispensers and/or feed stocks (not shown). For example, the a first fuel source can be introduced via a first airtight dispenser and/or feed stock, in which a second fuel source can be introduced via second airtight dispenser and/or feed stock. Without being
PATENT Attorney Docket No.: ACHM/0002PC bound by theory, a plurality of feedstocks can allow for enhanced throughout of the gasifier system, thereby increasing the total amount of product gas. [0052] In some embodiments, the steam from the heat source 106 and the fuel source 110 can be introduced at a ratio of about 0.5 to about 5.0 of steam to fuel source 110, e.g., about 0.5 to about 4.75, about 0.75 to about 3.5, or about 1.0 to about 1.5. In some embodiments, the steam from the heat source 106 and the fuel source 110 can be introduced to provide a steam to carbon ratio of 1.0 to about 5.0, e.g., about 1.0 to about 4.8, about 1.2 to about 2.6, or about 1.4 to about 1.5. [0053] In some embodiments, the fuel source 110 is heated by the fluidizing medium in the gasification chamber 101 to a temperature of about 500 °C to about 1000 °C, e.g., about 500 °C, about 600 °C, about 700 °C, about 800 °C, about 900 °C, about 1000 °C. The fuel source 110 can be heated by the fluidizing medium, pyrolyzed, and gasified in the gasification chamber 101. In some embodiments, the fuel source 110 is carbonized in the gasification chamber 101. In some embodiments, volatile components of the fuel sources injected into the gasification chamber 101 may be instantaneously gasified, and then solid carbon (char) may be gasified relatively slowly compared to the volatile components. The airtight dispenser may be equipped with dehydration means such as vacuum pump and/or super critical CO2. [0054] In some embodiments, residual carbonized char or lighter components may flow into the combustion chamber through the overflow chute 108. In some embodiments, the light components or char introduced from the gasification chamber 101 is combusted in the char combustion chamber 102, in which steam 111 is produced. The steam 111 may be reintroduced to the gasification chamber 101 as a heat source for the fluidizing medium through a plurality of steam orifices located within the fluidizing medium. [0055] In some embodiments, the fluidizing medium in the overflow chute 108 and/or the settling isolation chamber 105 can provide a seal between the
PATENT Attorney Docket No.: ACHM/0002PC char combustion gases and the gasification gases. The seal can control a pressure balance between the gasification chamber 101 and the char combustion chamber 102, thereby preventing the combustion gases and the gasification gases from mixing with each other. Without being bound by theory, by preventing the combustion gases and the gasification gases from mixing the properties, e.g., lower heating value, of the gasification gases may be maintained, reducing the amount of degradation of the gasification gases. [0056] In some embodiments, a concentration of fluidizing medium may flow into the overflow chute108 from the gasification chamber 101 may be similar to a concentration of fluidizing medium that flows from the settling isolation chamber 107 into the gasification chamber. Without being bound by theory, by having an input of fluidizing medium into the gasification chamber 101 and an output of the fluidizing medium out of the gasification chamber 101 be balanced, a mechanical delivery apparatus, e.g., a conveyor line, may be avoided. By eliminating a mechanical delivery apparatus, a reduction in the difficulty in handling high-temperature particles and/or fluidizing medium can occur. Moreover, an increase in the amount of heat retention during the transport of the fluidizing medium from the char combustion chamber 102 and the gasification chamber 101 can occur, increasing efficiency of the system 100. [0057] In some embodiments, the fuel source 110 may flow through the system 100 based on the fluidizing medium moving through the system 100. The residence time of the fuel source 110 in the gasification chamber may be controlled by the amount of fluidizing medium recirculation in the system 100. The amount of fluidizing recirculation may be controlled based on the air supply line 109 and/or the steam 111. Moreover, the amount of fluidizing recirculation may be controlled based on the density of the fluidizing medium. Without being bound by theory, the residence time may be controlled to allow for enhanced gasification of the fuel source 100 while maintaining suitable recirculation of the fluidizing medium to ensure consistent and/or uniform heat transfer from the fluidizing medium to the fuel source 110.
PATENT Attorney Docket No.: ACHM/0002PC [0058] Now referring to Figure 2, a system for reforming a biomass using a coaxially integrated gasification furnace is described. Biomass may be reformed using the coaxially integrated furnace as described above. In an embodiment, product gas 112 emitted from the gasification cyclone separator 103 may proceed to a water scrubber, oil scrubber, and sulfur absorbing tower. The product gas 112 may then be transferred to a gas holder, in which the product gas 112 may be utilized for a gas engine or a flare stack. Alternatively, the product gas 112 may be transferred through a gas dryer and proceed to a gas compressor to be used in a micro gas turbine. Alternatively, the product gas 112 may be processed in a methanol synthesis reactor to produce methanol. [0059] In an embodiment, the exhaust gas 113 emitted from the combustion cyclone separator 104 may proceed to a gas cooler, to produce an ash that may be removed from the furnace. Remaining exhaust gas 113 from the gas cooler may be processed in a super heater and air heater and filtered for residual particulates in the gas. Remaining nitrous oxide chemicals may be removed from the exhaust gas 113 and ejected via a smoke stack. In some embodiments, the exhaust gas 113 may be recirculated to the system 100 to be used as a non-oxidizer gas, e.g., a pneumatic gas for recirculating fluidizing medium, thereby reducing manufacturing costs. [0060] Figure 3 is a schematic diagram illustrating a system for producing electrical power using a coaxially integrated gasification furnace, according to an embodiment of the disclosure. Electrical power may be produced using the one or more product gases 112 ejected from the gasification cyclone separators 103. In an embodiment, product gas 112 emitted from the gasification cyclone separator 103 may proceed to a scrubber and desulfurization facility. The product gas 112 may then be transferred to a gas holder, in which the product gas 112 may be utilized to produce electrical power using a micro gas turbine or gas engine. Alternatively, the product gas 112 may be processed in a methanol synthesis facility to produce methanol.
PATENT Attorney Docket No.: ACHM/0002PC [0061] In an embodiment, the exhaust gas 113 emitted from the combustion cyclone separator 104 may proceed to a gas cooler, to produce an ash that may be removed from the furnace. Remaining exhaust gas 113 from the gas cooler may be processed in a pre-heater and filtered for residual particulates in the exhaust gas 113. Remaining nitrous oxide chemicals may be removed from the exhaust gas 113 and ejected via a smoke stack. [0062] Figure 4 is a schematic diagram illustrating a system for capturing carbon using a gasifier, according to an embodiment of the disclosure. The gasifier 401 emits product gas 112 from the gasification cyclone separators 103. In an embodiment, product gas 112 emitted from the gasification cyclone separator 103 may proceed to a steam reformer 402. The steam reformer 402 produces a reformed gas 404 by removing sulfur, water, oil, or combinations thereof from the product gas 112. The steam reformer 402 allows for condensate 405 of the product gas 112 to be transferred to a steam boiler 406, via a steam return 407. The condensate 405 is then heated in the steam boiler 406 and may be re-introduced to the steam reformer 402 as steam 408. [0063] The reformed gas 404 may then be transferred to a CO2 stripping module 409. The CO2 stripping module 409 removes CO2 from the reformed gas 404 to product an H2 rich gas 410 that may be extracted from the system. The stripped gas 411 has CO2 that is saturated with amines, which is transferred to an amine recovery module 412. The amine recovery module 412 removes one or more amines from the gas and reintroduces degassed amines 413 into the CO2 stripping module 409. Remaining amines may be transferred to the steam boiler to be re-introduced into the reform gas. [0064] From the amine recovery module 412 liquid CO2414 is transferred to a CO2 upcycling module 415. The CO2 upcycling module 415 emits recovered oil 416, in which the recovered oil may be utilized external to the system. Alternatively, the CO2 upcycling module 415 exhausts liquid CO2417, which may be recovered and removed from the system.
PATENT Attorney Docket No.: ACHM/0002PC [0065] Figure 5 is a schematic diagram illustrating a gasifier system 500, according to an embodiment of the disclosure. In some embodiments, an air supply 502 supplies one or more gases to the gasification chamber 101, the char combustion chamber 102, the settling isolation 105, and/or the overflow chute 108 via the air supply line 109. The air supply 502 can provide about 0.5 kg/hr to about 2,000 kg/hr of the one or more gases to the gasification chamber 101, the char combustion chamber 102, the settling isolation chamber 105, and/or the overflow chute 108, e.g., about 0.5 kg/hr to about 9.7 kg/hr, about 0.7 kg/hr to about 9.7 kg/hr, about 1.2 kg/hr to about 9.7 kg/hr, or about 9.0 kg/hr to about 9.7 kg/hr. In some embodiments, one or more valves 504a-d may control the flow of the one or more gases to the gasification chamber 101, the combustion chamber 102, the overflow chute, and the settling isolation chamber 105, respectively. [0066] In some embodiments, the one or more valves 504a-d can be opened and/or closed based on an input signal from a computing device 532. In some embodiments, a computing device 532 can include one or more of a processor, a network interface, a display, or a combination thereof. In some embodiments, a sensor (not shown) may be coupled to the one or more valves 504a-d to identify an amount of the one or more gases in the air supply line 109, in which the computing device 532 can transmit a signal to open and/or close the one or more valves 504a-d based on the sensor. [0067] In some embodiments, a steam generator 506 supplies steam to the gasification chamber 101 and/or the settling isolation chamber 105 via a steam supply line 508. The steam generator 506 can provide a steam mass flow rate of about 0.05 kg/hr to about 2.0 kg/hr to the gasification chamber 101 and/or the settling isolation chamber 105, e.g., about 0.05 kg/hr to about 1.8 kg/hr, about 1.2 kg/hr to about 1.6 kg/hr, or about 1.3 kg/hr to about 1.5 kg/hr. The steam generator 506 can provide a steam volume flow rate of about 5 m3/hr to about 15 m3/hr to the gasification chamber 101 and/or the settling isolation chamber 105, e.g., about 5 m3/hr to about 12 m3/hr, about 8 m3/hr to about 12
PATENT Attorney Docket No.: ACHM/0002PC m3/hr, or about 11 m3/hr to about 12 m3/hr. The steam generator 506 can provide the steam at a pressure of about 1 atm to about 2.0 atm to the gasification chamber 101 and/or the settling isolation chamber 105, e.g., about 1.0 atm to about 1.8 atm, about 1.2 atm to about 1.7 atm, about 1.3 atm to about 1.6 atm, or about 1.4 atm to about 1.6 atm. In some embodiments, the steam generator 506 can introduce the steam to the gasification chamber 101 and/or the settling isolation chamber 105 at a temperature of about 200 °C to about 1000 °C, e.g., about 200 °C, about 300 °C , about 400 °C , about 500 °C, about 600 °C, about 700 °C, about 800 °C, about 900 °C, or about 1000 °C. [0068] In some embodiments, one or more valves 510a or 510b may control the flow of the one or more gases to the gasification chamber 101 or the settling isolation chamber 105, respectively. In some embodiments, the one or more valves 510a or 510b can be opened and/or closed based on an input signal from a computing device 532, as described in the present disclosure. In some embodiments, a sensor (not shown) may be coupled to the one or more valves 510a or 510b to identify an amount of the steam in the steam supply line 508, in which the computing device 532 can transmit a signal to open and/or close the one or more valves 510a or 510b based on the sensor. [0069] In some embodiments, a supplemental gas 512 is introduced to the gasification chamber 101 via a supplemental supply line 514. The supplemental gas 512 can include one or more of a reactive carbon gas, e.g., alkanes, such as methane, ethane, propane, butane, pentane, hexane, heptane, octane, nonane, decane, or a combination thereof, alkenes, such as ethylene, propylene, butylene, pentylene, hexene, heptene, octene, nonene, decene, or a combination thereof, or alkylenes, such as ethyne, propyne, or the like, or nitrogen. For example, the supplemental gas 512 can include propane. In some embodiments, the one or more product gases 112 can be routed to the supplemental gas line 514 and introduced to the gasification chamber 101 as the supplemental gas 512 (not shown).
PATENT Attorney Docket No.: ACHM/0002PC [0070] The supplemental gas 512 can be introduced at a mass flow rate of about 0.05 kg/hr to about 16,000 kg/hr to the gasification chamber 101, e.g., about 0.05 kg/hr to about 15,000 kg/hr, about 1.2 kg/hr to about 12,000 kg/hr, or about 1.3 kg/hr to about 10,000 kg/hr. The supplemental gas 512 can be introduced at a volume flow rate of about 5 m3/hr to about 6,000 m3/hr to the gasification chamber 101, e.g., about 5 m3/hr to about 5,000 m3/hr, about 8 m3/hr to about 4,000 m3/hr, or about 11 m3/hr to about 3,000 m3/hr. The supplemental gas 512 can be introduced at a pressure of about 1 atm to about 2.0 atm to the gasification chamber 101, e.g., about 1.0 atm to about 1.8 atm, about 1.2 atm to about 1.7 atm, about 1.3 atm to about 1.6 atm, or about 1.4 atm to about 1.6 atm. The supplemental gas 512 can be introduced to the gasification chamber 101 at a temperature of about 200 °C to about 1000 °C, e.g., about 200 °C, about 300 °C , about 400 °C , about 500 °C, about 600 °C, about 700 °C, about 800 °C, about 900 °C, or about 1000 °C. [0071] In some embodiments, a valve 516 may control the flow of the supplemental gas 512 to the gasification chamber 101. In some embodiments, the valve 516 can be opened and/or closed based on an input signal from a computing device 532, as described in the present disclosure. In some embodiments, a sensor (not shown) may be coupled to the valve 516 to identify an amount of supplemental gas 512 being introduced to the gasification chamber 101, in which the computing device 532 can transmit a signal to open and/or close the valve 516 based on the sensor. [0072] In some embodiments, an alternative supplemental gas can be introduced to gasification chamber 102. The alternative supplemental gas can modify and/or adjust a chemical reaction in the gasification chamber such that the product gas composition can be controlled. In some embodiments, a sensor (not shown) may be coupled to the alternative supplemental gas source to identify an amount of alternative supplemental gas being introduced to the gasification chamber 101, in which the computing device 532 can transmit a signal to open and/or close the valve based on the sensor.
PATENT Attorney Docket No.: ACHM/0002PC [0073] In some embodiments, a sensor 518 is coupled to the gasification chamber 101, in which the sensor 518 can identify one or more temperature of the gasification chamber 101 and/or the fluidizing medium. In some embodiments, the valves 504a-d, 510a-b, or 516 can be opened and/or closed based on an input signal from a computing device 532, as described in the present disclosure, based on the sensor 518. For example, the sensor 518 may indicate that a temperature of the gasification chamber 101 is about 700 °C, in which the computing device 532 may open one or more of valves 504a-d to introduce one or more gases from the air supply line 109 to reduce the temperature to about 650 °C. Without being bound by theory, the sensor 518 can allow for enhanced control of the temperature of the gasification chamber 101 and/or the fluidizing medium. [0074] In some embodiments, a sensor 520 is coupled to the gasification chamber 101, in which the sensor 520 can identify a volume of the fluidizing medium in the gasification chamber 101. In some embodiments, the valves 504a-d, 510a-b, or 516 can be opened and/or closed based on an input signal from a computing device 532, as described in the present disclosure, based on the sensor 520. Moreover, a fluidizing medium 526 may be introduced to the char combustion chamber 102, in which the fluidizing medium 526 may overflow from the char combustion chamber 102 to the settling isolation chamber 105, and subsequently to the gasification chamber 101. For example, the sensor 520 may indicate that a volume of fluidizing medium 526 in the gasification chamber 101 is about 0.005 m3, in which the computing device 532 may introduce additional fluidizing medium 526 via the char combustion chamber 102. Alternatively, the sensor 520 may indicate that a volume of fluidizing medium 526 in the gasification chamber 101 is about 0.006 m3, in which the computing device 532 may open one or more of valves 504a-d to pulse and/or flow additional air such that more fluidizing medium enters the char combustion chamber relative to the gasification chamber. Without being bound by theory, the sensor 520 can allow for enhanced control of the volume of fluidizing medium 526 in the gasification chamber 101.
PATENT Attorney Docket No.: ACHM/0002PC [0075] In some embodiments, a sensor 522 is coupled to the char combustion chamber 102, in which the sensor 522 can identify one or more temperature of the char combustion chamber 522 and/or the fluidizing medium. In some embodiments, the valves 504a-d, 510a-b, or 516 can be opened and/or closed based on an input signal from a computing device 532, as described in the present disclosure, based on the sensor 522. For example, the sensor 522 may indicate that a temperature of the char combustion chamber 102 is about 800 °C, in which the computing device 532 may open one or more of valves 510a or 510b to introduce steam from the steam supply line 508 to increase the temperature to about 850 °C. Without being bound by theory, the sensor 522 can allow for enhanced control of the temperature of the char combustion chamber 102 and/or the fluidizing medium. [0076] In some embodiments, a sensor 524 is coupled to the settling isolation chamber 105, in which the sensor 524 can identify a volume of the fluidizing medium in the settling isolation chamber 105. In some embodiments, the valves 504a-d, 510a-b, or 516 can be opened and/or closed based on an input signal from a computing device 532, as described in the present disclosure, based on the sensor 524. Moreover, a fluidizing medium 526 may be introduced to the char combustion chamber 102, in which the fluidizing medium 526 may overflow from the char combustion chamber 102 to the settling isolation chamber 105. Without being bound by theory, the sensor 524 can allow for enhanced control of the volume of fluidizing medium 526 in the char combustion chamber 105. [0077] In some embodiments, a sensor 525 is coupled to the settling isolation chamber 105, in which the sensor 525 can identify one or more temperature of the settling isolation chamber 105 and/or the fluidizing medium. In some embodiments, the valves 504a-d, 510a-b, or 516 can be opened and/or closed based on an input signal from a computing device 532, as described in the present disclosure, based on the sensor 522. For example, the sensor 522 may indicate that a temperature of the settling isolation chamber 105 is about
PATENT Attorney Docket No.: ACHM/0002PC 600 °C, in which the computing device 532 may open one or more of valves 510a or 510b to introduce steam from the steam supply line 508 to increase the temperature to about 650 °C. Without being bound by theory, the sensor 525 can allow for enhanced control of the temperature of the settling isolation chamber 105 and/or the fluidizing medium. [0078] In some embodiments, a sensor 528 is coupled to the exhaust gas 113, in which the sensor 528 analyzes the exhaust gas 113 to determine the presence of one or more oxygen species, e.g., carbon monoxide, carbon dioxide, nitrogen oxide, or a combination thereof. In some embodiments, a valve 530 can be opened and/or closed based on an input signal from a computing device 532, as described in the present disclosure, based on the sensor 528. For example, the valve 530 can be opened to allow the exhaust gas 113 to be collected as product gas, when the exhaust gas 113 contains reduced and/or no oxygenated species. As a further example, the valve 530 can be closed to prevent the exhaust gas 113 from being collected as product gas, when the exhaust gas 113 contains oxygenated species. Without being bound by theory, the sensor 530 can allow for selective control exhaust gas collection, thereby increasing the overall yield of the system 500. Moreover, and without being bound by theory, the sensor 530 may have enhanced accuracy when the air supply line pulses the one or more gases into the gasification chamber 101, thereby allowing an air/fuel equivalence ratio to be monitored and the fluidizing medium to reach a target temperature before being transported to the gasification chamber. [0079] In some embodiments, an analyzer (not shown) is coupled to the fuel source 110. The analyzer can include an elemental analyzer capable of analyzing one or more fuel sources using spectroscopy and/or spectrometry. For example, the analyzer can include a laser abrasion spectroscopy instrument. As a further example, the analyzer can include a mass spectrometer. In some embodiments, the computing device 532 can receive a signal from the analyzer and transmit a signal to adjust one or more of the flow
PATENT Attorney Docket No.: ACHM/0002PC rates of the one or more gases, steam, supplemental gases, or a combination thereof. In some embodiments, the computing device 532 can receive a signal from the analyzer and transmit a signal to adjust one or more of the temperatures of the gasification chamber 101, the char combustion chamber 102, or the settling isolation chamber 105. [0080] FIG.6 is a flow diagram illustrating a gasifier system 600, according to an embodiment of the disclosure. At operation 602 a start routine is performed by a computing device 532 of a gasifier system 500. The start routine can include performing a safety check of one or more of the gasification chamber 101, char combustion chamber 102, settling isolation chamber 105, air supply 502, steam generator 506, valves 504a-d, valves 510a and 510b, valve 516, valve 530, or a combination thereof. The start routine can include performing an operational confirmation of one or more of the gasification chamber 101, char combustion chamber 102, settling isolation chamber 105, air supply 502, steam generator 506, valves 504a-d, valves 510a and 510b, valve 516, valve 530, sensor 518, sensor 520, sensor 522, sensor 524, sensor 528, or a combination thereof. In some embodiments, the computing device 532 can transmit a signal to the gasification chamber 101, char combustion chamber 102, settling isolation chamber 105, air supply 502, steam generator 506, valves 504a-d, valves 510a and 510b, valve 516, valve 530, sensor 518, sensor 520, sensor 522, sensor 524, sensor 528, or a combination thereof, in which the computing device may confirm safety and/or operational viability by receiving a returning signal. [0081] At operation 604 the computing device 532 obtains a recipe. The computing device 532 can obtain the recipe by an input, e.g., user input via a display device. The recipe can include one or more operating parameters for each of the gasification chamber 101, char combustion chamber 102, settling isolation chamber 105, air supply 502, steam generator 506, valves 504a-d, valves 510a and 510b, valve 516, valve 530, sensor 518, sensor 520, sensor 522, sensor 524, sensor 528, or a combination thereof. For example, the recipe
PATENT Attorney Docket No.: ACHM/0002PC can include a gasification chamber temperature of 650, a char combustion chamber of 850, a settling isolation chamber temperature of 650 and a flow rate of about 0.5 kg/hr to about 10 kg/hr of the one or more gases from the air supply. [0082] At operation 606 one or more gases are introduced to the gasification chamber 101, the char combustion chamber 102 and/or the settling isolation chamber 105. The one or more gases can include one or more gases supplied from the air supply 502, via the air supply line 109. In some embodiments, the air supply line 109 can provide about 0.5 kg/hr to about 10 kg/hr of the one or more gases, e.g., about 0.5 kg/hr to about 9.7 kg/hr, about 0.7 kg/hr to about 9.7 kg/hr, about 1.2 kg/hr to about 9.7 kg/hr, or about 9.0 kg/hr to about 9.7 kg/hr. The one or more gases can include a steam supplied from the steam generator 506, via the steam supply line 508. The steam generator 506 can provide a steam mass flow rate of about 0.05 kg/hr to about 2.0 kg/hr, e.g., about 0.05 kg/hr to about 1.8 kg/hr, about 1.2 kg/hr to about 1.6 kg/hr, or about 1.3 kg/hr to about 1.5 kg/hr. The steam generator 506 can provide a steam volume flow rate of about 5 m3/hr to about 15 m3/hr, e.g., about 5 m3/hr to about 12 m3/hr, about 8 m3/hr to about 12 m3/hr, or about 11 m3/hr to about 12 m3/hr. The one or more gases can include a supplemental gas 512 supplied via the supplemental supply line 514. The supplemental gas 512 can be introduced at a mass flow rate of about 0.05 kg/hr to about 800 kg/hr, e.g., about 0.05 kg/hr to about 700 kg/hr, about 1.2 kg/hr to about 600 kg/hr, or about 1.3 kg/hr to about 500 kg/hr. The supplemental gas 512 can be introduced at a volume flow rate of about 5 m3/hr to about 600 m3/hr, e.g., about 5 m3/hr to about 500 m3/hr, about 8 m3/hr to about 400 m3/hr, or about 11 m3/hr to about 300 m3/hr. [0083] In some embodiments, the one or more gases can be introduced to the gasification chamber 101, the char combustion chamber 102 and/or the settling isolation chamber 105 when one or more of valves 504a-d, valves 510a and 510b, valve 516, valve 530 are in an open state. In some embodiments, where valves 510a and/or 510b are open, the steam may be introduced to the gasification chamber 101, the char combustion chamber 102, and/or the settling
PATENT Attorney Docket No.: ACHM/0002PC isolation chamber 105 to increase the temperature of the gasifier system 100. In some embodiments the one or more gases may be restricted and/or prevented from entering the gasification chamber 101, the char combustion chamber 102 and/or the settling isolation chamber 105 when one or more of valves 504a-d, valves 510a and 510b, valve 516, valve 530 are in a closed state. [0084] At operation 608 a fuel source 110 is introduced to the gasification chamber 101. In some embodiments, the fuel source 110 can be introduced to the gasification chamber 101 at a flow rate of about 2 kg/day to about 20 tons/day, e.g., about 2.1 kg/day to about 700 kg/day, about 10 kg/day to about 600 kg/day, or about 40 kg/day to about 50 kg/day. In some embodiments, the fuel source 110 can be introduced to the gasification chamber 101 to provide a carbon content flow of about 1.0 kg/hr to about 100 kg/hr, e.g., about 1.0 kg/hr to about 3/0 kg/hr, about 1.5 kg/hr to about 2.5 kg/hr, or about 1.7 kg/hr to about 2.0 kg/hr. [0085] At operation 610 a product gas 112 is obtained from the gasification chamber 101 via the gasification cyclone separator 103. In some embodiments, about 1.0 kg/hr to about 3.0 kg/hr of product gases 112 can be obtained from the gasification chamber 101 via the gasification cyclone separator 103, e.g., about 1.0 kg/hr to about 2.5 kg/hr, about 1.2 kg/hr to about 2.0 kg/hr, or about 1.4 kg/hr to about 1.6 kg/hr. In some embodiments, about 0.1 Nm3/kW to about 0.3 Nm3/kW of the product gas 112 can be obtained from the gasification chamber 101 via the gasification cyclone separator 103, e.g., about 0.1 Nm3/kW to about 0.25 Nm3/kW, about 0.15 Nm3/kW to about 0.2 Nm3/kW, or about 0.17 Nm3/kW to about 0.19 Nm3/kW. In some embodiments, about 1.0 Nm3/kg to about 5.0 Nm3/kg of the product gas 112 can be obtained from the gasification chamber 101 via the gasification cyclone separator 103, e.g., about 1.0 Nm3/kg to about 4.0 Nm3/kg, about 1.5 Nm3/kg to about 3.5 Nm3/kg, or about 2.0 Nm3/kg to about 2.2 Nm3/kg. In some embodiments, about 1.0 Nm3/kg to about 5.0 Nm3/kg of the product gas 112 can be obtained from the gasification
PATENT Attorney Docket No.: ACHM/0002PC chamber 101 via the gasification cyclone separator 103, e.g., about 1.0 Nm3/kg to about 4.0 Nm3/kg, about 1.5 Nm3/kg to about 3.5 Nm3/kg, or about 2.0 Nm3/kg to about 2.2 Nm3/kg. [0086] FIG.7 is a flow diagram illustrating a method 700 of gasifying a fuel source, according to an embodiment of the disclosure. At operation 702 a fluidizing medium is heated in a gasification chamber 101, a char combustion chamber 102, and a settling isolation chamber 105. The fluidizing medium is heated to a temperature of about 500 °C to about 1000 °C, e.g., about 500 °C, about 600 °C, about 700 °C, about 800 °C, about 900 °C, about 1000 °C. The fluidizing medium is heated by introducing steam, from a steam generator 506, via a steam supply line 508. The steam can be introduced at a steam mass flow rate of about 0.05 kg/hr to about 2.0 kg/hr, e.g., about 0.05 kg/hr to about 1.8 kg/hr, about 1.2 kg/hr to about 1.6 kg/hr, or about 1.3 kg/hr to about 1.5 kg/hr. The steam generator 506 can provide a steam volume flow rate of about 5 m3/hr to about 15 m3/hr, e.g., about 5 m3/hr to about 12 m3/hr, about 8 m3/hr to about 12 m3/hr, or about 11 m3/hr to about 12 m3/hr. [0087] At operation 704, a fuel source 110 is injected to the gasification chamber 101. In some embodiments, the fuel source 110 can be injected at a flow rate of about 2 kg/day to about 20 tons/day, e.g., about 2.1 kg/day to about 20 kg/day, about 10 kg/day to about 18 kg/day, or about 15 kg/day to about 20 kg/day. In some embodiments, the fuel source 110 can be injected into the gasification chamber 101 to provide a carbon content flow of about 1.0 kg/hr to about 2.1 kg/hr, e.g., about 1.0 kg/hr to about 2.0 kg/hr, about 1.5 kg/hr to about 2.0 kg/hr, or about 1.7 kg/hr to about 2.0 kg/hr. [0088] In some embodiments, the fuel source 110 can be introduced to the gasification chamber 101 via a plurality of airtight dispensers and/or feed stocks (not shown). For example, the a first fuel source can be introduced via a first airtight dispenser and/or feed stock, in which a second fuel source can be introduced via second airtight dispenser and/or feed stock. Without being
PATENT Attorney Docket No.: ACHM/0002PC bound by theory, a plurality of feedstocks can allow for enhanced throughout of the gasifier system, thereby increasing the total amount of product gas. [0089] In some embodiments, the steam from the heat source 106 and the fuel source 110 can be introduced at a ratio of about 0.5 to about 5.0 of steam to fuel source 110, e.g., about 0.5 to about 4.75, about 0.75 to about 3.5, or about 1.0 to about 1.5. In some embodiments, the steam from the heat source 106 and the fuel source 110 can be introduced to provide a steam to carbon ratio of 1.0 to about 5.0, e.g., about 1.0 to about 4.8, about 1.2 to about 2.6, or about 1.4 to about 1.5. [0090] At operation 706, the fuel source 110 is gasified by contacting the fuel source 110 with the fluidizing medium in the gasification chamber 101. The fuel source can be gasified by heating the fuel source 110 with the fluidizing medium in the gasification chamber 101 to a temperature of about 500 °C to about 1000 °C, e.g., about 500 °C, about 600 °C, about 700 °C, about 800 °C, about 900 °C, about 1000 °C. The fuel source 110 can be heated by the fluidizing medium, pyrolyzed, and gasified in the gasification chamber 101. In some embodiments, the fuel source 110 is carbonized in the gasification chamber 101. In some embodiments, volatile components of the fuel sources injected into the gasification chamber 101 may be instantaneously gasified, and then solid carbon (char) may be gasified relatively slowly compared to the volatile components. The airtight dispenser may be equipped with dehydration means such as vacuum pump and/or super critical CO2. [0091] At operation 708, a product gas 112 is obtained from the gasification chamber 101. The product gas 112 is obtained from the gasification chamber 101 via the gasification cyclone separator 103. In some embodiments, about 1.0 kg/hr to about 3.0 kg/hr of product gases 112 can be obtained from the gasification chamber 101 via the gasification cyclone separator 103, e.g., about 1.0 kg/hr to about 2.5 kg/hr, about 1.2 kg/hr to about 2.0 kg/hr, or about 1.4 kg/hr to about 1.6 kg/hr. In some embodiments, about 0.1 Nm3/kW to about 0.3 Nm3/kW of the product gas 112 can be obtained from the gasification chamber
PATENT Attorney Docket No.: ACHM/0002PC 101 via the gasification cyclone separator 103, e.g., about 0.1 Nm3/kW to about 0.25 Nm3/kW, about 0.15 Nm3/kW to about 0.2 Nm3/kW, or about 0.17 Nm3/kW to about 0.19 Nm3/kW. In some embodiments, about 1.0 Nm3/kg to about 5.0 Nm3/kg of the product gas 112 can be obtained from the gasification chamber 101 via the gasification cyclone separator 103, e.g., about 1.0 Nm3/kg to about 4.0 Nm3/kg, about 1.5 Nm3/kg to about 3.5 Nm3/kg, or about 2.0 Nm3/kg to about 2.2 Nm3/kg. In some embodiments, about 1.0 Nm3/kg to about 5.0 Nm3/kg of the product gas 112 can be obtained from the gasification chamber 101 via the gasification cyclone separator 103, e.g., about 1.0 Nm3/kg to about 4.0 Nm3/kg, about 1.5 Nm3/kg to about 3.5 Nm3/kg, or about 2.0 Nm3/kg to about 2.2 Nm3/kg [0092] At operation 710, a residual carbonized char and a portion of the fluidizing medium are directed to an overflow chute 108 of the gasification chamber 101. The overflow chute 108 is fluidly coupled to the char combustion chamber. In some embodiments, directing the portion fluidizing medium to the overflow chute can provide a first seal between the gasification chamber 101 and the char combustion chamber 102. The first seal can control a pressure balance between the gasification chamber 101 and the char combustion chamber 102, thereby preventing the combustion gases and the gasification gases from mixing with each other. Without being bound by theory, by preventing the combustion gases and the gasification gases from mixing the properties, e.g., lower heating value, of the gasification gases may be maintained, reducing the amount of degradation of the gasification gases. [0093] At operation 712, the residual carbonized char and the portion of the fluidizing medium are heated in the char combustion chamber 102. The char combustion chamber 102 can heat the residual carbonized char and the portion of the fluidizing medium to a temperature of about 500 °C to about 1000 °C using a heat source 106, the heat source 106 can emit heat via an electromagnetic wave such as microwave radiation, radio frequency radiation, infrared radiation, or ultraviolet radiation, inductive heating, and/or steam. For
PATENT Attorney Docket No.: ACHM/0002PC example, the heat source can introduce steam to the char combustion chamber 102 at a steam mass flow rate of about 0.05 kg/hr to about 1,200 kg/hr, e.g., about 0.05 kg/hr to about 1,100 kg/hr, about 1.2 kg/hr to about 1,000 kg/hr, or about 300 kg/hr to about 1,200 kg/hr. As a further example, the heat source 106 can introduce steam to the char combustion chamber 102 at a steam volume flow rate of about 5 m3/hr to about 15 m3/hr, e.g., about 5 m3/hr to about 12 m3/hr, about 8 m3/hr to about 12 m3/hr, or about 11 m3/hr to about 12 m3/hr. [0094] At operation 714, an exhaust gas 113 is obtained from the char combustion chamber 102. In some embodiments, the exhaust gases 113 can include carbon dioxide, nitrogen, nitrogen oxide, water, or a combination thereof. In some embodiments, the exhaust gas 113 can be obtained by directing the exhaust gas 113 to a char combustion cyclone separator 104. In some embodiments, the combustion cyclone separator 104 can emit about 1.0 kg/hr to about 3.0 kg/hr of exhaust gases 113, e.g., about 1.0 kg/hr to about 2.5 kg/hr, about 1.2 kg/hr to about 2.0 kg/hr, or about 1.4 kg/hr to about 1.6 kg/hr. In some embodiments, the combustion cyclone separator 104 can emit about 1.0 kg/day to about 20 tons/day of exhaust gases 113, e.g., about 1.0 kg/day to about 18 tons/day, about 5.0 kg/day kg/hr to about 15 tons/day, or about 10 kg/day to about 10 tons/day. [0095] At operation 716, the portion of the fluidizing medium is collected in the settling isolation chamber 105. The fluidizing medium in the char combustion cyclone separator 104 may lose energy and fall down towards the settling isolation chamber 105, in which the fluidizing medium may build up in the settling isolation chamber 105. In some embodiments, collecting the portion of the fluidizing medium in the settling isolation chamber can provide a second seal between the gasification chamber 101 and the char combustion chamber 102. The second seal can control a pressure balance between the gasification chamber 101 and the char combustion chamber 102, thereby preventing the combustion gases and the gasification gases from mixing with each other. Without being bound by theory, by preventing the combustion gases and the
PATENT Attorney Docket No.: ACHM/0002PC gasification gases from mixing the properties, e.g., lower heating value, of the gasification gases may be maintained, reducing the amount of degradation of the gasification gases. [0096] At operation 718, the portion of the fluidizing medium in the settling isolation chamber 105 is directed to the gasification chamber 101 by flowing one or more gases from an air supply line 109 to the settling isolation chamber 105 or the char combustion chamber 102. In some embodiments, the one or more gases can be supplied from an air supply 502, via the air supply line 109. In some embodiments, the air supply line 109 can provide about 0.5 kg/hr to about 10 kg/hr of the one or more gases, e.g., about 0.5 kg/hr to about 9.7 kg/hr, about 0.7 kg/hr to about 9.7 kg/hr, about 1.2 kg/hr to about 9.7 kg/hr, or about 9.0 kg/hr to about 9.7 kg/hr. EXAMPLES [0097] Energy Consumption and Steam to Fuel Ratio [0098] An energy consumption relative to a temperature was determined for a gasifier system 100 using varying steam to fuel source ratios, e.g., 0.5, 0.75, 1.0, 1.25, 1.5, and 2.0. An increase in the steam to fuel ratio increased the energy consumption of the gasifier system, as shown in FIG.8A. However, an increase in the steam to fuel source ratio resulted in a product gas having the lowest LHV, as shown in FIG. 8B. Alternatively, a steam to fuel ratio of about 1.0 about 1.51resulted in a product gas having the highest LHV, as shown in FIG.9. [0099] Product Gas Composition [0100] A first product gas (reference 1) and second product gas (reference 2) of conventional gasifier systems was compared to a product gas of the gasifier system of the present disclosure when operating at a steam to fuel ratio of 1 (example 1) and 1.25 (example 2), as shown in FIG.10.
PATENT Attorney Docket No.: ACHM/0002PC [0101] Gasifier Efficiency [0102] A gas efficiency relative to a temperature was determined for a gasifier system 100 using varying steam to fuel source ratios, e.g., 1.0, 1.25, 1.5, and 2.0. Cold gas, e.g., the product gas energy value, recovery of the gasification chamber 101 resulted in no difference was found between the steam to fuel source ratios, as shown in FIG. 11A. Hot gas, e.g., product gas having enthalpy of the fluid, recovery of the gasification chamber 101 resulted in a steam to fuel ratio about 1.25 or 1.5 had the highest efficiency, as shown in FIG.11B. [0103] Fluidizing medium size [0104] A first fluidizing medium having a first particle size of about 247 μm was simulated in the gasifier system 100 and a volume fraction was determined at each of 0.25 seconds (s), 0.5 s, 1 s, and 1.5 s. After 1.5 s the volume fraction in the settling isolation chamber 105 was reduced, while the volume fraction in the gasification chamber 101 increased, as shown in FIG. 12A. A second fluidizing medium having a second particle size of about 2470 μm was simulated in the gasifier system 100 and a volume fraction was determined at each of 0.25 seconds (s), 0.5 s, 1 s, and 1.5 s. After 1.5 s the volume fraction in the settling isolation chamber 105 and the gasification chamber 101 remained stable, indicating a stable balance of fluidizing medium across the settling isolation chamber 105 and the gasification chamber 101, as shown in FIG.12B. ENUMERATED EMBODIMENTS [0105] E1. A coaxially integrated gasification furnace, including: a gasification chamber fluidly coupled to a gasification cyclone separator; a char combustion chamber fluidly coupled to a combustion cyclone separator, wherein the char combustion chamber is located within the gasification chamber; a settling isolation chamber having a first partition and a second partition, wherein the first partition separates the settling isolation chamber from
PATENT Attorney Docket No.: ACHM/0002PC the combustion chamber, and the second partition separates the settling isolation chamber from the gasification chamber; and at least a temperature control element disposed on the settling isolation chamber. [0106] E2. The furnace of embodiment E1, wherein the char combustion chamber comprises a transparent wall configured to allow one or more electromagnetic waves of light to pass through the transparent wall. [0107] E3. The furnace of embodiment E1 or E2, further comprising a fluidizing medium disposed in the gasification chamber and the settling isolation chamber, wherein the fluidizing medium comprises sand. [0108] E4. The furnace of any one of embodiments E1-E3, further comprising an overflow chute located within the gasification chamber. [0109] E5. The furnace of any one of embodiments E1-E4, further comprising a heat source coupled to the gasification chamber, the char combustion chamber, and the settling isolation chamber. [0110] E6. The furnace of any one of embodiments E1-E5, wherein the heat source comprises an electromagnetic wave heat source. [0111] E7. A gasification system including: a coaxially integrated gasification furnace, wherein the coaxially integrated gasification furnace comprises: a gasification chamber fluidly coupled to a gasification cyclone separator; a char combustion chamber fluidly coupled to a combustion cyclone separator, wherein the char combustion chamber is located within the gasification chamber; a settling isolation chamber having a first partition and a second partition, wherein the first partition separates the settling isolation chamber from the combustion chamber, and the second partition separates the settling isolation chamber from the gasification chamber; and at least a temperature control element disposed on the settling isolation chamber an air supply line fluidly coupled to the gasification chamber, the char combustion chamber, and the settling isolation chamber; a steam supply line fluidly coupled
PATENT Attorney Docket No.: ACHM/0002PC to the gasification chamber, the char combustion chamber, and the settling isolation chamber; and one or more valves fluidly coupled to the air supply line or the steam supply line. [0112] E8. The system of embodiment E7, wherein the char combustion chamber comprises a transparent wall configured to allow one or more electromagnetic waves of light to pass through the transparent wall. [0113] E9. The system of embodiment E8, wherein the transparent wall comprises quartz. [0114] E10. The system of embodiment E8 or E9, further comprising a supplemental gas line coupled to the gasification chamber, wherein the supplemental gas line comprises a supplemental gas comprising propane. [0115] E11. The system of any one of embodiments E7-E10, wherein the steam supply line is fluidly coupled to the gasification chamber and the settling isolation chamber of the coaxially integrated gasification furnace. [0116] E12. The system of any one of embodiments E7-E11, wherein the air supply line is fluidly coupled to the gasification chamber, the char combustion chamber, and the settling isolation chamber of the coaxially integrated gasification furnace. [0117] E13. The system of any one of embodiments E7-E12, further comprising a fluidizing medium disposed in the gasification chamber and the settling isolation chamber, wherein the fluidizing medium comprises sand. [0118] E14. A method of gasifying a fuel source, the method comprising: heating a fluidizing medium in a gasification chamber, a char combustion chamber, and a settling isolation chamber of a gasification system to a temperature of about 500 °C to about 1000 °C by introducing a steam; injecting a fuel source to the gasification chamber; gasifying the fuel source by contacting the fuel source with the fluidizing medium in the gasification
PATENT Attorney Docket No.: ACHM/0002PC chamber; obtaining a product gas from the gasification chamber; directing a residual carbonized char and a portion of the fluidizing medium to an overflow chute of the gasification chamber, the overflow chute fluidly coupled to the char combustion chamber; heating the residual carbonized char and at least a portion of the fluidizing medium in the char combustion chamber; obtaining an exhaust gas from the char combustion chamber; collecting the portion of the fluidizing medium in the settling isolation chamber; and directing the portion of the fluidizing medium in the settling isolation chamber to the gasification chamber by flowing one or more gases from an air supply line to the settling isolation chamber or the char combustion chamber. [0119] E15. The method of embodiment E14, wherein directing the portion fluidizing medium to the overflow chute further comprises providing a first seal between the gasification chamber and the char combustion chamber. [0120] E16. The method of embodiment E14 or E15, wherein collecting the portion of the fluidizing medium in the settling isolation chamber comprises providing a second seal between the gasification chamber and the char combustion chamber. [0121] E17. The method of any one of embodiments E14-E16, wherein obtaining the exhaust gas further comprises directing the exhaust gas to a char combustion cyclone separator. [0122] E18. The method of any one of embodiments E14-E17, wherein the steam and the fuel source are introduced to the gasification chamber at a ratio of about 0.5 to about 5.0 of steam to fuel source. [0123] E19. The method of any one of embodiments E14-E18, wherein the steam and the fuel source are introduced to the gasification chamber at a ratio of about 1.0 to about 2.0 of steam to fuel source.
PATENT Attorney Docket No.: ACHM/0002PC [0124] E20. The method of any one of embodiments E14-E19, wherein the fuel source is introduced to the gasification chamber at a flow rate of about 2 kg/day to about 20 tons/day. [0125] Overall, the present disclosure is directed to a coaxially integrated gasification system that provides increased efficiency compared to conventional gasification systems. The gasification system can reduce operating expenses by limiting the use of manual fluidizing movement due to the coaxial arrangement. Moreover, the gasification system can gasify a plurality of fuel sources, including coal, biomass, and/or municipal waste. The system can provide enhanced recovery of energy from gasifying fuel sources when compared to conventional gasification systems. Additionally, the coaxially integrated gasification system can provide a controllable gasifier system with an ability to independently control one or more of the fluidizing temperature, infrared emission, steam temperature, steam flow rate, air temperature, air flow rate, combustion temperature, gasification temperature, pneumatic flow rates, additives, or a combination thereof by implementing one or more sensors in the system. While the foregoing is directed to embodiments of the present disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
Claims
PATENT Attorney Docket No.: ACHM/0002PC What is claimed is: 1. A coaxially integrated gasification furnace comprising: a gasification chamber fluidly coupled to a gasification cyclone separator; a char combustion chamber fluidly coupled to a combustion cyclone separator, wherein the char combustion chamber is located within the gasification chamber; a settling isolation chamber having a first partition and a second partition, wherein the first partition separates the settling isolation chamber from the combustion chamber, and the second partition separates the settling isolation chamber from the gasification chamber; and at least a temperature control element disposed on the settling isolation chamber. 2. The furnace of claim 1, wherein the char combustion chamber comprises a transparent wall configured to allow one or more electromagnetic waves to pass through the transparent wall. 3. The furnace of claim 1, further comprising a fluidizing medium disposed in the gasification chamber and the settling isolation chamber, wherein the fluidizing medium comprises sand. 4. The furnace of claim 1, further comprising an overflow chute located within the gasification chamber. 5. The furnace of claim 1, further comprising a heat source coupled to the gasification chamber, the char combustion chamber, and the settling isolation chamber. 6. The furnace of claim 1, wherein the heat source comprises an electromagnetic wave heat source.
PATENT Attorney Docket No.: ACHM/0002PC 7. A gasification system comprising: a coaxially integrated gasification furnace, wherein the coaxially integrated gasification furnace comprises: a gasification chamber fluidly coupled to a gasification cyclone separator; a char combustion chamber fluidly coupled to a combustion cyclone separator, wherein the char combustion chamber is located within the gasification chamber; a settling isolation chamber having a first partition and a second partition, wherein the first partition separates the settling isolation chamber from the combustion chamber, and the second partition separates the settling isolation chamber from the gasification chamber; and at least a temperature control element disposed on the settling isolation chamber an air supply line fluidly coupled to the gasification chamber, the char combustion chamber, and the settling isolation chamber; a steam supply line fluidly coupled to the gasification chamber, the char combustion chamber, and the settling isolation chamber; and one or more valves fluidly coupled to the air supply line or the steam supply line. 8. The system of claim 7, wherein the char combustion chamber comprises a transparent wall configured to allow one or more electromagnetic waves to pass through the transparent wall. 9. The system of claim 8, wherein the transparent wall comprises quartz. 10. The system of claim 7, further comprising a supplemental gas line coupled to the gasification chamber, wherein the supplemental gas line comprises a supplemental gas comprising propane.
PATENT Attorney Docket No.: ACHM/0002PC 11. The system of claim 7, wherein the steam supply line is fluidly coupled to the gasification chamber and the settling isolation chamber of the coaxially integrated gasification furnace. 12. The system of claim 7, wherein the air supply line is fluidly coupled to the gasification chamber, the char combustion chamber, and the settling isolation chamber of the coaxially integrated gasification furnace. 13. The system of claim 7, further comprising a fluidizing medium disposed in the gasification chamber and the settling isolation chamber, wherein the fluidizing medium comprises sand. 14. A method of gasifying a fuel source, the method comprising: heating a fluidizing medium in a gasification chamber, a char combustion chamber, and a settling isolation chamber of a gasification system to a temperature of about 500 °C to about 1000 °C by introducing a steam; injecting a fuel source to the gasification chamber; gasifying the fuel source by contacting the fuel source with the fluidizing medium in the gasification chamber; obtaining a product gas from the gasification chamber; directing a residual carbonized char and a portion of the fluidizing medium to an overflow chute of the gasification chamber, the overflow chute fluidly coupled to the char combustion chamber; heating the residual carbonized char and at least a portion of the fluidizing medium in the char combustion chamber; obtaining an exhaust gas from the char combustion chamber; collecting the portion of the fluidizing medium in the settling isolation chamber; and directing the portion of the fluidizing medium in the settling isolation chamber to the gasification chamber by flowing one or more gases from an
PATENT Attorney Docket No.: ACHM/0002PC air supply line to the settling isolation chamber or the char combustion chamber. 15. The method of claim 14, wherein directing the portion fluidizing medium to the overflow chute further comprises providing a first seal between the gasification chamber and the char combustion chamber. 16. The method of claim 14, wherein collecting the portion of the fluidizing medium in the settling isolation chamber comprises providing a second seal between the gasification chamber and the char combustion chamber. 17. The method of claim 14, wherein obtaining the exhaust gas further comprises directing the exhaust gas to a char combustion cyclone separator. 18. The method of claim 14, wherein the steam and the fuel source are introduced to the gasification chamber at a ratio of about 0.5 to about 5.0 of steam to fuel source. 19. The method of claim 18, wherein the steam and the fuel source are introduced to the gasification chamber at a ratio of about 1.0 to about 2.0 of steam to fuel source. 20. The method of claim 19, wherein the fuel source is introduced to the gasification chamber at a flow rate of about 20 kg/day to about 20 tons/day.
Applications Claiming Priority (4)
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| US202363449225P | 2023-03-01 | 2023-03-01 | |
| US63/449,225 | 2023-03-01 | ||
| US202363455735P | 2023-03-30 | 2023-03-30 | |
| US63/455,735 | 2023-03-30 |
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| WO2024182640A2 true WO2024182640A2 (en) | 2024-09-06 |
| WO2024182640A3 WO2024182640A3 (en) | 2024-11-07 |
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| Application Number | Title | Priority Date | Filing Date |
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| PCT/US2024/017924 Ceased WO2024182640A2 (en) | 2023-03-01 | 2024-02-29 | Coaxially stacked coaxial fuel gasifier |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN120799452A (en) * | 2025-09-16 | 2025-10-17 | 山西江阳工程爆破有限公司 | Waste heat destroying device |
Family Cites Families (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4032305A (en) * | 1974-10-07 | 1977-06-28 | Squires Arthur M | Treating carbonaceous matter with hot steam |
| US4315758A (en) * | 1979-10-15 | 1982-02-16 | Institute Of Gas Technology | Process for the production of fuel gas from coal |
| US7285144B2 (en) * | 1997-11-04 | 2007-10-23 | Ebara Corporation | Fluidized-bed gasification and combustion furnace |
| CA2314986C (en) * | 1997-12-18 | 2008-03-25 | Ebara Corporation | Fuel gasification system |
| US20080230444A1 (en) * | 2004-02-03 | 2008-09-25 | Yuki Iwadate | Hydrocarbon Material Processing System and Method |
| WO2008107928A1 (en) * | 2007-03-01 | 2008-09-12 | Ihi Corporation | Method for gasification in fluidized bed |
| JP6935482B2 (en) * | 2019-12-27 | 2021-09-15 | 荏原環境プラント株式会社 | Pyrolysis equipment and pyrolysis method |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN120799452A (en) * | 2025-09-16 | 2025-10-17 | 山西江阳工程爆破有限公司 | Waste heat destroying device |
| CN120799452B (en) * | 2025-09-16 | 2025-11-14 | 山西江阳工程爆破有限公司 | A waste thermal destruction device |
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