Classifications

• • 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
  • C10J3/005—Rotary drum or kiln gasifiers
• • 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
  • C10J1/00—Production of fuel gases by carburetting air or other gases without pyrolysis
  • C10J1/26—Production of fuel gases by carburetting air or other gases without pyrolysis using raised temperatures or pressures
• • 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
• • 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
  • C10J2200/00—Details of gasification apparatus
  • C10J2200/15—Details of feeding means
  • C10J2200/158—Screws
• • 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
  • C10J2300/09—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
• • 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
  • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
  • C10J2300/0953—Gasifying agents
  • C10J2300/0956—Air or oxygen enriched air
• • 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
  • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
  • C10J2300/0953—Gasifying agents
  • C10J2300/0973—Water
  • C10J2300/0976—Water as steam
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
  • Y02P20/00—Technologies relating to chemical industry
  • Y02P20/10—Process efficiency
  • Y02P20/129—Energy recovery, e.g. by cogeneration, H2recovery or pressure recovery turbines

Definitions

• the present application relates generally to waste and waste stream processing, and more particularly to converting varied source industry wastes into energy.
• wastes that are harmful to the environment. These wastes manifest in the form of solids, liquids, and gases that many times find their way deep into the ground to pollute underground water resources. The wastes also find their way into water streams that eventually meet rivers thereby polluting the rivers. If/when these wastes are sent to a landfill, they tend to disintegrate into most potent greenhouse gases such as methane.
• wastes have been incinerated in an attempt to reduce the amount of waste generated by manufacturing processes. Incineration of the wastes has been used to recover energy from the wastes.
• incineration processes has various drawbacks. For example, incineration of these wastes causes emissions of more toxic gases such as dioxins and furans into the air. Furthermore, incineration completely rules out production of gaseous fuel from the wastes as an energy source because during incineration none of the hydrocarbons of the wastes survive in a combustible form.
• the present disclosure generally provides an improved gasification apparatus, system, and method for processing varied source wastes containing hydrocarbons. This results in a single apparatus, system, or method to process hydrocarbon-containing materials produced from various stages of manufacturing processes, thereby increasing environmental stewardship.
• the system and method include the use of a gasification apparatus comprising a rotary kiln reactor and a gas distributor.
• the rotary kiln reactor and gas distributor are configured to generate multiple reaction environments within the gasification apparatus. Each of the reaction environments has unique temperature and pressure conditions that process various components of the hydrocarbon-containing wastes.
• Gasification is a process by which hydrocarbon-containing materials/wastes are converted into a combustible mixture of gases including carbon monoxide, hydrogen, methane, water vapor, and carbon dioxide.
• This combustible mixture of gases has the potential of providing a direct source of energy to industry and to manufacturing processing, or it can be used as fuel for generating steam and or electricity for manufacture processing.
• the conversion of the combustible mixture of gases into energy uses an improved gasification method, as described herein, which is amenable to complete utilization of all hydrocarbon-containing wastes generated by manufacturing and industry processes. This results in less environmental pollution and considerable savings for the manufacturing industry.
• FIG. 1 is a side cross-section view of an apparatus/gasifier for processing hydrocarbon- containing wastes according to the present disclosure
• FIG. 2A is a perspective view of a gas distributor of the apparatus/gasifier according to the present disclosure
• FIG. 2B is an end view of the gas distributor of the apparatus/gasifier according to the present disclosure.
• FIGS. 3A through 3D are end cross-section views of the apparatus/gasifier depicting effects of varying rotation speeds of a rotary kiln reactor of the apparatus/gasifier according to the present disclosure
• FIG. 4 is a system block flow diagram illustrating system components for processing hydrocarbon-containing wastes according to the present disclosure
• FIG. 5 is a process flow diagram illustrating methods for processing hydrocarbon- containing wastes according to the present disclosure
• FIG. 6 is a system block flow diagram illustrating an exemplary use of the present disclosure in converting industry wastes into gaseous fuel
• FIG 7 is an illustration of use of the present invention in converting another type of industry waste into gaseous fuel.
• FIG 8 is an illustration of the present invention in converting yet another type of industry waste into gaseous fuel.
• the present disclosure generally relates to an improved gasification apparatus, system, and method for processing hydrocarbon-containing wastes.
• the system and method include the use of a gasification apparatus comprising a rotary kiln reactor and a gas distributor.
• the rotary kiln reactor and gas distributor are configured to generate multiple reaction environments within the gasification apparatus.
• Each of the reaction environments has unique temperature and pressure conditions that process various components of the hydrocarbon-containing wastes. This is beneficial because it enables processing of varied-source hydrocarbon-containing wastes with widely varying physical and chemical properties.
• the apparatus 100 includes a rotary kiln reactor 102 that provides a first stage of gas-solid reactions in the apparatus 100.
• the rotary kiln reactor 102 is designed to produce optimum gas-solid interaction of hydrocarbon and non-hydrocarbon- containing wastes with gases.
• the rotary kiln reactor 102 may include a means 104 (such as a conveyor or screw feeder) for introducing hydrocarbon solids and liquids into the rotary kiln reactor 102, gas inlets 106 for introducing gas into the rotary kiln reactor 102 using a gas distributor 108, a means 110 for introducing water into the rotary kiln reactor 102, a means 112 for removing solids from the rotary kiln reactor 102, and a means 114 for removing gas from the rotary kiln reactor 102. Solids/ash are removed from the apparatus 100 at a rate commensurate with the presence of noncombustible fraction present in the incoming waste.
• An inner surface of the rotary kiln reactor 102 may be lined with refractory 116 so that the rotary kiln reactor 102 may be operated at a temperature up to about 2200°F.
• the gas distributor 108 may be divided into four or more zones.
• the number of zones the gas distributor 108 has may depend upon the length of the apparatus 100 and/or the rotary kiln reactor 102. According to non- limiting, illustrative examples, the gas distributor 108 may have as little as 2 zones and as many as 8 zones. However, one skilled in the art should appreciate the gas distributor having other numbers of zones without departing from the scope of the present disclosure.
• each respective zone of the gas distributor 108 receives gas from a single gas inlet 106. However, one skilled in the art should appreciate that each zone may receive gas from more than one gas inlet 106. Each zone may receive a unique composition and quantity of gas from one or more gas inlets 106 that are distinct from gas compositions received by other zones of the gas distributor 108.
• the gas distributor 108 may be a tubular structure having a circular or nearly circular cross-section (as depicted in FIG. 2B). Moreover, the gas distributor 108 may be a stationary structure supported at or proximate ends 202 thereof by the rotary kiln reactor 102. Support by the rotary kiln reactor 102 may occur through the use of stationary hoods.
• Each zone of the gas distributor 108 includes gas outlet ports 204 through which gas from the gas inlets 106 are introduced into the apparatus 100.
• Each zone of the gas distributor 108 may contain equal numbers of gas ports or each zone may contain a unique number of gas ports different from those of other zones. The number of gas ports each zone has may depend upon the maximum amount of gas to be introduced at that zone and the pressure at which the gases are available.
• the gas ports are located long about 180 degrees of the circumference of a tubular portion 206 of the gas distributor.
• a movable overlay 210 is fitted to the tubular portion 206 of the gas distributor 108.
• the movable overlay 208 is a half-spherical structure that covers about 180 degrees of the circumference of the tubular portion 206.
• the overlay 208 may be capable of covering all or substantially all of the gas outlet ports 204 while in a single orientation.
• the overlay 208 covering more or less than 180 degrees of the tubular portion 206, less than substantially all of the gas outlet ports 204, and having any shape that allows it to mate with the tubular portion 206 without departing from the scope of the present disclosure.
• the movable overlay 208 is configured to rotate about the tubular portion 206 to direct the flow of gas through the gas outlet ports 204 within desired ranges. For example, the movable overlay 208 may be moved to cover less gas outlet ports 204 when less pressure is desired and more gas outlet ports 204 when more pressure is desired.
• the composition of the gas distributor 108 and overlay pipe 208 may be selected to withstand temperature of up to about 2200°F.
• the hydrocarbon-containing wastes may be conveyed into the rotary kiln reactor 102 using a solid conveyer 104 such as a screw feeder, for example.
• the screw feeder 104 uses a rotating screw blade to move the hydrocarbon-containing wastes into the rotary kiln reactor 102.
• Water may be introduced into the rotary kiln reactor 102 via a water inlet 110.
• the water may be introduced at rate of about 25% to about 30% by weight of that of the varied- source hydrocarbon-containing waste on dry basis.
• the hydrocarbon-containing wastes may be in gas, solid and/or liquid states.
• the gases introduced into the gas distributor 108 may be oxygen and/or non-oxygen bearing.
• the gases may be delivered into the rotary kiln reactor 102 in varying quantities and compositions along the length of the rotary kiln reactor 102 in a manner that allows the gases to contact the hydrocarbon-containing wastes along a wall of the rotary kiln reactor 102.
• Distribution of the gases along the length of the rotary kiln reactor 102 may be achieved by varying the lengths of the gas inlets 106 within the rotary kiln reactor 102.
• each gas inlet 106 may have a length different from lengths of the other gas inlets 106.
• two or more of the gas inlets 106 having equal or substantially equal lengths without departing from the spirit and scope of the present disclosure.
• the apparatus 100 of the present disclosure while being configured to perform the above identified interactions and transformations, may also be configured to dry and devolatilize hydrocarbon-containing wastes, to remove and destroy agents of organic contamination in inorganic materials including soils, as well as to produce bio-chars from biomasses without necessitating physical alternation of the apparatus 100.
• the apparatus 100 may be configured to perform only a portion of the above identified operations at a time, in which case switching between configurations to perform the different operations may be automatic and instantaneous.
• the apparatus 100 operates independent of the type of hydrocarbon-containing wastes, thereby enabling hydrocarbon-containing wastes with varying compositions and physical properties to be processed by the apparatus 100 without needing to alter the apparatus 100 in any material way.
• the apparatus 100 also operates independent of the size of the hydrocarbon- containing wastes introduced therein, thereby allowing hydrocarbon-containing wastes of varying sizes to be processed by the apparatus 100 without needing to alter the apparatus 100 in any material way.
• the apparatus 100 may process hydrocarbon-containing wastes ranging from about 0.1 inches to about 6 inches, and preferably from about 0.1 inches to about 2 inches.
• the apparatus 100 may be configured to permit passage of gas through the apparatus 100 that is about 40 times greater in weight than that of the hydrocarbon- containing wastes introduced into and processed by the rotary kiln reactor 102. In another example, the apparatus 100 may be configured to permit passage of gas through apparatus 100 that is about 20 times greater in weight than that of the hydrocarbon-containing wastes introduced into and processed by the rotary kiln reactor 102.
• the apparatus 100 may perform processing operations at a range of temperatures including about 100°F to about 3000°F, and preferably from about 100°F to about 2200°F.
• the apparatus 100 may also perform processing operations at a range of pressures, including pressure within the apparatus 100 being about minus 1 inch of water column to about 100 inches of water column.
• FIGS. 3A through 3D operational conditions within the rotary kiln reactor 102 are described. While the rotary kiln reactor 102 is exemplarily illustrated as rotating counter clockwise, the rotary kiln reactor 102 is not limited to merely counter clockwise rotation.
• the inlet means 104 e.g., described above with reference to FIG. 1
• inertial forces caused by rotation of the rotary kiln reactor 102 cause solids within the hydrocarbon-containing wastes 302 to gravitate to an outer wall 304 of the rotary kiln reactor 102.
• the rotary kiln reactor 102 may rotate prior to introduction of the hydrocarbon-containing wastes 302 or may not start rotating until after the hydrocarbon-containing wastes 302 are introduced therein.
• the amount of surface area coverage of the hydrocarbon-containing wastes 302 along the surface area of the outer wall 304 of the rotary kiln reactor 102 depends on the speed of rotation of the rotary kiln reactor 102.
• solids of the hydrocarbon-containing wastes 302 settle at the bottom of the rotary kiln reactor 102.
• FIG. 3B illustrates low rotation speed
• FIG. 3C illustrates medium rotation speed
• the solids of the hydrocarbon-containing wastes 302 become more disbursed along the outer wall 304, thereby covering a larger surface area of the outer wall 304.
• Relative positions of the gas distributor 108 and the overlay pipe 208 may be altered to adjust or modify trajectories of the gas outlet ports 204 with respect to the interior of the rotary kiln reactor 102 (demonstrated, e.g., by a comparison of the gas distributor 108 and the overlay pipe 208 within FIGS. 3, 4 through 3D).
• the gas distributor 108 and the overlay pipe 208 may be configured to direct a maximum amount of a contact between gases dispersed from the gas outlet ports 204 and the hydrocarbon-containing wastes 302.
• wet hydrocarbon-containing wastes may be dried within the apparatus 100, namely within the rotary kiln reactor 102. While the wet hydrocarbon-containing wastes are in the rotary kiln reactor 102, hot gases are entered into the rotary kiln reactor 102 via the gas outlet ports 204. The hot gases may have a temperature of about 300°F to about 1000°F. Prior to introduction into the rotary kiln reactor 102, the wet hydrocarbon-containing wastes may be at room temperature. Preferable drying of wet hydrocarbon-containing wastes is attained when the hot gases are uniformly distributed within the four zones of the gas distributor 108.
• the dried hydrocarbon-containing wastes are discharged from the rotary kiln reactor 102 as ash via the means 112 for removing solids from the rotary kiln reactor 102.
• the apparatus 100 may perform pyro lysis of the hydrocarbon-containing wastes by heating hydrocarbon solids to a temperature in the range of about 800°F to about 1000°F, at which time volatile matter present in the hydrocarbon-containing wastes is vaporized.
• the volatile matter comprises mainly large molecule hydrocarbons, small molecule hydrocarbons, combustible gases including carbon monoxide and hydrogen, and non-combustible gases including carbon dioxide, nitrogen and water.
• the hydrocarbon-containing wastes are introduced into the rotary kiln reactor 102 where they are contacted with hot gases introduced into the rotary kiln reactor 102 through the gas distributor 108.
• Vaporization of the hydrocarbon-containing wastes may also occur using the following methodology.
• the hydrocarbon-containing wastes are partially combusted to generate adequate heat to raise the temperature of the hydrocarbon-containing wastes to about 800°F to about 1000°F.
• the rotary kiln reactor 102 Prior to introduction of hydrocarbon-containing wastes, the rotary kiln reactor 102 is heated to a temperature above an ignition temperature of the hydrocarbon-containing wastes. Oxygen-bearing gases used to ignite the hydrocarbon-containing wastes are introduced into the rotary kiln reactor 102 through the gas distributor 108. Room temperature hydrocarbon- containing wastes are introduced into the preheated rotary kiln reactor 102.
• Introduction of the room temperature hydrocarbon-containing wastes into the rotary kiln reactor 102 may occur prior, during, or after the oxygen-bearing gases are introduced into the rotary kiln reactor 102.
• Beneficial results for the pyrolysis of the hydrocarbon-containing wastes using this method are attained when the oxygen-bearing gases are uniformly distributed throughout the four zones of the gas distributor 108.
• the hydrocarbon-containing wastes are partially combusted.
• the heat of combustion causes the temperature of the hydrocarbon- containing wastes to rise to about 800°F to about 1000°F, at which time volatiles contained in the hydrocarbon-containing wastes evaporate into a gaseous phase.
• the general reactions or schematic reactions involved in this pyrolysis methodology include the following:
• the solid residue discharged from the rotary kiln reactor 102 contains inorganic components of the hydrocarbon-containing wastes as well as fixed carbon present in the hydrocarbon-containing wastes. This solid residue has clean burning properties and is therefore considered high-grade solid fuel.
• the hydrocarbon- containing wastes employed during this pyrolysis methodology is biomass, the solid residue discharged from the rotary kiln reactor 102 constitutes bio-char.
• the hydrocarbon- containing wastes are reacted with oxygen bearing gases (i.e., air) and water (i.e., vapor) at an elevated temperature to convert hydrocarbon-containing material into a mixture of combustible and non-combustible gases.
• the fuel gas mixture may include carbon monoxide, hydrogen, methane, ethane, carbon dioxide, water vapour, and nitrogen. Additionally, the fuel gas mixture may have a caloric value in the range of about 80 to about 320 BTU per cubic foot irrespective of a composition of the varied- source hydrocarbon-containing waste processed/gasified.
• room temperature hydrocarbon-containing wastes are introduced into the kiln reactor 102, which is preheated to a temperature above an ignition temperature of the hydrocarbon- containing wastes.
• Oxygen-bearing gases are used to ignite the hydrocarbon-containing wastes and are introduced into the rotary kiln reactor 102 through the gas distributor 108.
• the hydrocarbon-containing wastes may have about 20% to about 50% water content. If the hydrocarbon-containing wastes do not contain a sufficient water content prior to introduction into the rotary kiln reactor 102, water is introduced to the hydrocarbon-containing wastes while in the rotary kiln reactor 102. Alternatively, instead of water, steam may be introduced to the hydrocarbon-containing wastes while in the rotary kiln reactor 102.
• the rotary kiln reactor 102 Upon entering the preheated rotary kiln reactor 102, a small amount of volatile matter from the hydrocarbon-containing wastes is instantly vaporized. Due to the rotary kiln reactor 102 being preheated to the volatile matter's flash point of combustion, the volatile material is instantaneously ignited when contacted with air or some other oxygen-bearing gas.
• the quantity of oxygen-bearing gases introduced along the length of the rotary kiln reactor 102 is far below that required for complete combustion of the hydrocarbon-containing wastes.
• the quantity of oxygen-bearing gases may be in the range of about 30%) to about 70%> percent by volume of that required for complete combustion of the hydrocarbon-containing wastes.
• the chemical composition of the hydrocarbon-containing wastes, the amount of moisture contained therein, and the intended temperature of the gasification reaction dictate the quantity of the oxygen bearing gases.
• the wastes generated by industry and manufacturing processes vary significantly in terms of their physical and chemical properties. In order to be able to process each of these wastes separately or in combination, suitable reaction conditions within the rotary kiln reactor 102 to align with the requirements of the wastes should be provided.
• the physical properties of hydrocarbon-containing wastes generally relate to size, density, and their moisture content. The physical properties require that the wastes are allotted certain residence time within the rotary kiln reactor 102 in order for the wastes to fully react with gaseous reactants within the bounds of the rotary kiln reactor 102.
• the ability of the present disclosure to increase localized temperatures within zones of the rotary kiln reactor 102 speeds up reactions within the rotary kiln reactor 102. In this manner, the apparatus 100 of the present disclosure is able to accommodate variations in the physical properties of received hydrocarbon-containing wastes.
• the chemical properties of the hydrocarbon-containing wastes are characterized by their elemental compositions and their volatility as determined by amount of volatile carbon content and fixed carbon contained within the wastes.
• the elemental composition determines the amount of oxygen-bearing gases as well as amount of water required to fully gasify the waste.
• the volatility dictates where the reaction gases are introduced for effective gasification of the waste. For example, a mixture of plastic waste and char includes almost 50% volatile carbon and 50% fixed carbon whereas textile waste includes of mostly volatile carbon. For gasification of plastics and char mixture, a gradual introduction of oxygen- bearing gases along the length of the rotary kiln reactor 102 is an effective mode for gasification.
• the reason for gradual introduction of reactant gases is that the volatile carbon has a tendency to instantly react with the reactant gases whereas the fixed carbon requires longer contact time with reactant gases for gasification reactions to take place.
• the rotary kiln reactor 102 of the present disclosure has the ability to introduce the reactant gases according to the dictate of the waste along the length of the rotary kiln reactor 102 through the zoned gas distributor 108.
• an effective mode for gasification includes introduction of most of the requisite oxygen- bearing gases and water in the zone close to where the waste is introduced into the rotary kiln reactor 102.
• all oxygen-bearing gases may enter in the first zone of the gas distributor 108.
• waste containing about equal parts of volatile carbon and fixed carbon is processed in a first zone, which may be closest to the entry of the hydrocarbon- containing material into the rotary kiln reactor 102, the temperature is maintained below about 800°F so the moisture contained in the hydrocarbon-containing material is evolved first, followed by partial evaporation of the volatile matter.
• a first zone about 10% to about 25% of the oxygen-bearing gases are introduced.
• the following reactions represent the interactions between the gas(es) and solid hydrocarbon-containing wastes:
• the second zone another about 10%> to about 25% of the oxygen-bearing gases are introduced to further combust the volatile matter, which continues to vaporize.
• the temperature is allowed to rise to about 1000°F to about 1200°F.
• the objective of the second zones configuration is to completely vaporize the volatile matter from the hydrocarbon- containing material.
• the third zone another about 25% to about 40% oxygen-bearing gases are introduced and directed towards the hydrocarbon-containing material, which should now be devoid of volatile matter but including fixed carbon and inorganic components of the hydrocarbon- containing wastes.
• the configuration of the third zone allows for full combustion of the fixed carbon.
• the temperature is allowed to rise to a range of about 1800°F to about 2000°F in order to accelerate combustion of the fixed carbon.
• the heavy hydrocarbons and the combustible gases present inside of the rotary kiln reactor 102 at the third zone also partially combust with the oxygen-bearing gas.
• the vapors of water present in the gas inside the rotary kiln reactor 102 at the third zone also react with the fixed carbon as well as with the heavy hydrocarbon molecules present in the vaporized volatile matter, thereby causing these molecules to break down into smaller hydrocarbon molecules and combustible gases comprising mainly carbon monoxide and hydrogen.
• the main reactions are as follows: C + 0 2 -> C0 2
• Hydrocarbon-containing wastes are directed from a storage 402 (e.g., a hopper) a gasifier (such as the apparatus 100) using a conveyor means (e.g., screw feeder) 404.
• the hydrocarbon-containing wastes may be processed by the gasifier/apparatus 100 using the functionality described herein.
• Gases introduced into the gasifer/apparatus 100, gases generated by reaction of the introduced gases with the hydrocarbon-containing wastes, and reacted ash generated in but not otherwise disposed of by the gasifer/apparatus 100 are directed to a cyclone 406. Additionally, solids/ash enter the cyclone 406 at a rate commensurate with the presence of a non-combustible fraction present in the hydrocarbon-containing waste. These gases and ash may have a temperature of about 1800°F. At the cyclone 406, at least a portion of the received ash is separated from the gases, and the ash is dispelled from the system. The gases remaining in the cyclone 406 may be cooled by two methods before they are utilized as source of energy. One method of cooling occurs by means of direct contact with water in a quencher 408. An alternative method for cooling the gas is by using an indirect means of contacting the gas with water in a Waste Heat Exchanger ("WHE”) 414.
• WHE Waste Heat Exchanger
• the gas Upon exiting the quencher 408 or upon exiting the WHE 414, the gas is further purified to remove additional ash using either a cyclone 410 or filter 416 before it is utilized by, for example, a burner 412.
• a surge tank 418 is included in the system 400 to mitigate surges in production of fuel gas from the gasification of hydrocarbon-containing wastes because of its variability with respect to physical and chemical properties.
• the gases may have a temperature of about 1800°F upon entering the quencher 408 and a temperature of about 350°F upon exiting the quencher 408.
• the gases may have a substantially constant temperature during transfer between the quencher 408 and burner 412, and between the WHE 414 and the burner 412.
• the constant temperature may be about 350° F.
• the gases may be about 1800°F while entering the WHE 414 and may be about 350°F while leaving the WHE 414. Lime may be introduced into the filter 416 to remove contaminants therein.
• FIG. 5 illustrates a method 500 for processing hydrocarbon-containing wastes according to the present disclosure.
• hydrocarbon-containing wastes are reacted with oxygen-bearing gases and water under at least three different reaction environments. This may be performed using the apparatus/gasifier 100.
• the hydrocarbon-containing wastes may have about 20% to about 50% water content.
• Oxygen- bearing gases are used in all or almost all of the reaction environments described below.
• the overall reaction may involve gasifying the hydrocarbon-containing wastes.
• a first reaction environment involves room temperature hydrocarbon-containing wastes entering the apparatus at which time at least a portion of the volatile matter of the hydrocarbon-containing wastes is instantly vaporized due to the apparatus being preheated to a temperature above the ignition temperature/flash point of combustion of the hydrocarbon-containing wastes.
• temperature of the apparatus is maintained below about 800°F, causing moisture contained in the hydrocarbon-containing wastes to evolve first, following by partial evaporation of the volatile matter.
• temperature of the apparatus is maintained between about 1000°F and about 1200°F, causing complete vaporization of the volatile matter from the hydrocarbon-containing wastes. This results in fixed carbon and inorganic components remaining in the hydrocarbon-containing wastes.
• a fourth reaction environment the apparatus is maintained in a range of about 1800°F to about 2000°F, causing combustion of the fixed carbon of the hydrocarbon-containing wastes.
• the conditions of the fourth reaction environment also results in heavy hydrocarbons combustible gases being partially combusted, as well as vapors of water reacting with the hydrocarbons to create smaller hydrocarbon molecules and combustible gases (e.g., carbon monoxide and hydrogen).
• a fifth reaction environment and subsequent reaction environments have similar conditions to those in the fourth reaction environment.
• solid residues resulting from the gasification of hydrocarbon-containing wastes are separated from the gases generated from the gasification of the hydrocarbon- containing wastes. This may be performed using the cyclone 406.
• gaseous hydrocarbon-containing wastes are quenched using direct contact with water. Quenching of the gaseous hydrocarbon-containing wastes may be performed using the quencher 408.
• additional solid residues are separated from the quenched gases generated from the gasification of the hydrocarbon-containing wastes. This may be performed using the quencher cyclone 410.
• the separated gases are combusted. Combustion of the said gases may be performed using the burner 412.
• thermal energy is captured by indirect means from hot gases generated from the gasification of hydrocarbon-containing wastes. This may be performed using the WHE 414.
• additional solid ash is separated from the hydrocarbon-containing wastes. This may be performed using the filters 416.
• the gases generated by the gasification of hydrocarbon-containing wastes are combusted as illustration of one utility of fuel gases generated by gasification of the hydrocarbon-containing wastes. This may be performed using the burner 412.
• Alternative options for utilization of the gases are direct replacement of fuels in industry and manufacturing processing, direct replacement of fuels in boilers for generating steam, and direct replacement of fuels in gas engines for generating electricity.
• the varied-source industry waste source utilized may be a combination of various wasted generated by a typical chemical processing plant.
• Exemplary components of the varied-industry wastes that may be processed by the system 600 are depicted in Table 1.
• the system 600 illustrates how the present disclosure may be utilized for recovering energy using 15 tons/day of varied-source waste in the form of steam and in the form of usable fuel gas.
• FIG. 7 illustrates how in practice the present invention would be utilized for recovering energy using 15 tons per day of another type of varied source waste in the form of steam and in the form of usable fuel gas.
• the distinguishing characteristics between the waste types in FIG. 6, FIG. 7, and FIG. 8 are their inherent calorific values which makes them different from the perspective of their chemical properties.
• the gases may enter the WHE 414 at a rate of about 2,110 kg/h, about 2,756 kg/h, or about 3,212 kg/h, for example.
• the gases may enter the quencher 408 at a rate of about 1,385 kg/h or about 1,400 kg/h, for example.
• the gases may enter the cyclone 410 at a rate of about 1,720 kg/h, about 1,820 kg/h, or about 1,920 kg/h, for example.
• the gases may enter the burner 412 at a rate of about 1,720 kg/h, about 1,820 kg/h, or about 1,920 kg/h, for example.
• the gases may enter the cyclone 406 at a rate of about 2,100 kg/h, about 2,756 kg/h, or about 3,212 kg/h, for example.
• the ash may be dispelled from the system at a rate of about 9.65 kg/h, about 6.80 kg/h, or about 3.88 kg/h, for example.

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• 2015
  • 2015-08-21 UA UAA201701740A patent/UA122211C2/uk unknown
  • 2015-08-21 EP EP15834115.6A patent/EP3183322A4/de active Pending
  • 2015-08-21 CA CA2959017A patent/CA2959017C/en active Active
  • 2015-08-21 US US15/505,891 patent/US20170275542A1/en not_active Abandoned
  • 2015-08-21 WO PCT/US2015/046257 patent/WO2016029093A1/en active Application Filing
  • 2015-08-21 CN CN201580056507.1A patent/CN107109260B/zh active Active
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