EP4026885A1 - Réacteur et procédé de gazéification et/ou de fusion de matières d'alimentation et de production d'hydrogène - Google Patents

Réacteur et procédé de gazéification et/ou de fusion de matières d'alimentation et de production d'hydrogène Download PDF

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Publication number
EP4026885A1
EP4026885A1 EP21150408.9A EP21150408A EP4026885A1 EP 4026885 A1 EP4026885 A1 EP 4026885A1 EP 21150408 A EP21150408 A EP 21150408A EP 4026885 A1 EP4026885 A1 EP 4026885A1
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Prior art keywords
section
gas
gas outlet
reactor
tuyere
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EP21150408.9A
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German (de)
English (en)
Inventor
André WEGNER
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Kbi Invest & Management Ag
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Kbi Invest & Management Ag
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Priority to EP21150408.9A priority Critical patent/EP4026885A1/fr
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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
    • C10J3/02—Fixed-bed gasification of lump fuel
    • C10J3/20—Apparatus; Plants
    • C10J3/22—Arrangements or dispositions of valves or flues
    • C10J3/24—Arrangements or dispositions of valves or flues to permit flow of gases or vapours other than upwardly through the fuel bed
    • C10J3/26—Arrangements or dispositions of valves or flues to permit flow of gases or vapours other than upwardly through the fuel bed downwardly
    • 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
    • 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
    • C10J2200/152—Nozzles or lances for introducing gas, liquids or suspensions
    • 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
    • C10J2200/156—Sluices, e.g. mechanical sluices for preventing escape of gas through the feed inlet
    • 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
    • C10J2300/0916—Biomass
    • 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
    • C10J2300/0916—Biomass
    • C10J2300/092—Wood, cellulose
    • 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
    • C10J2300/0959—Oxygen
    • 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
    • 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
    • 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
    • C10J2300/0983—Additives
    • C10J2300/0989—Hydrocarbons as additives to gasifying agents to improve caloric properties
    • 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
    • C10J2300/1625—Integration of gasification processes with another plant or parts within the plant with solids treatment
    • C10J2300/1628—Ash post-treatment
    • C10J2300/1634—Ash vitrification
    • 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
    • C10J2300/18—Details of the gasification process, e.g. loops, autothermal operation
    • C10J2300/1838—Autothermal gasification by injection of oxygen or steam
    • 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
    • C10J2300/18—Details of the gasification process, e.g. loops, autothermal operation
    • C10J2300/1846—Partial oxidation, i.e. injection of air or oxygen only

Definitions

  • This invention relates to a reactor and a method for gasifying and/or melting of substances and further the production of hydrogen.
  • the invention relates to the material and/or energy recovery of any waste, for example, but not exclusively plastic waste, household waste, used tires, hazardous waste, asbestos, hospital waste, coal or coal dust. During recovery, the reactor may also produce hydrogen.
  • the reactor and the method are also suitable for the gasifying and melting of feed materials of any composition or for the generation of energy through the use of waste and/or coal.
  • EP 1 261 827 B1 discloses a reactor for the gasifying and/or melting of feed materials. This reactor does not follow the approach of the previously frequently used circulating gas process. In contrast, the disclosed reactor operates according to a combined co-current and countercurrent principle. The complete elimination of conventional recirculation gas management avoids many of the problems associated with the condensation of pyrolysis products and the formation of unwanted deposits. Furthermore, EP 1 261 827 B1 discloses that already in the upper part of the reactor a partial conglomeration of the feed materials takes place due to the shock-like heating of the bulk material (bulk column), whereby adherences to the inner wall of the reactor are largely excluded. In EP 1 261 827 B1 it is disclosed that a reduction section is formed between two injection means through which all gases flow before extraction, thereby reducing them to a large extent.
  • Waste removal and hydrogen production have been processed in different reactors, plants and businesses.
  • One problem to be solved by the present invention is therefore to provide an improved reactor for producing hydrogen and simultaneously gasifying and melting of feed materials and an improved method for producing hydrogen and simultaneously gasifying and melting of feed materials.
  • This and other problems are solved by the reactor specified in claim 1.
  • This reactor combines simultaneously gasifying and melting of feed materials and hydrogen production in the same reactor, and by this synergy, reduces cost.
  • the reactor according to claim 1 comprises an upper co-current section, a central gas outlet section and a lower countercurrent section.
  • the gas flows downwards to the gas outlet section.
  • the gas flows from below the gas outlet section to the gas outlet section. The gas escapes via at least one gas outlet in the gas outlet section.
  • the co-current section comprises a plenum section, an upper oxidation section and an upper reduction section.
  • the gas flows parallel with the bulk.
  • the bulk which is the feed material fed into the reactor via a feed section, forms within the reactor a fixed bed, which moves continuously through the reactor in the direction of the reactor bottom.
  • the plenum section comprises a feed section with at least one sluice (e.g. a material lock, which may be a rotary lock, load-lock and/or an air-lock), a buffer section, a pre-treatment section and an intermediate section.
  • a sluice e.g. a material lock, which may be a rotary lock, load-lock and/or an air-lock
  • feed materials e.g. waste materials, such as used tires, hazardous waste, asbestos waste, toxic hospital waste, industrial waste, electronic waste, coal and/or coal dust, non-recyclable plastic, wood or paper, light/coarse ASR (automotive shredder residues) and/or MSW (municipal solid waste) or the like, can be fed into the reactor from above.
  • waste materials such as used tires, hazardous waste, asbestos waste, toxic hospital waste, industrial waste, electronic waste, coal and/or coal dust, non-recyclable plastic, wood or paper, light/coarse ASR (automotive shredder residues) and/or MSW (municipal solid waste) or the like
  • ASR automotive shredder residues
  • MSW munal solid waste
  • hatches can preferably be designed in such a way that the hatches are additionally closed in the event of unintentional overpressure in the reactor and no gas can escape unintentionally.
  • pressure equalization lines may be provided to the atmosphere or other areas of the reactor. Due to this embodiment, the hatches can also be opened at the desired overpressure in the reactor, since the hatches' drive does not have to work against a pressure difference.
  • the plenum section also includes a buffer section for buffering and pre-drying the feed material volume.
  • the buffer section is also made of normal or creep-resistant steel.
  • the temperature of the buffer section is preferably adjustable. For example, a set temperature of approx. 100°C to 200°C can be provided for the pre-drying of waste.
  • a pre-treatment section is provided in the plenum section, which is located below the bottom of the buffer section by creating a cross-sectional enlargement in the upper portion, the cross-sectional enlargement being preferably abrupt.
  • the cross-section area of the upper portion of the pre-treatment section increases at least twice compared to the cross-section area of the buffer section.
  • the cross-section narrows.
  • the pre-treatment section is preferably refractory lined.
  • the roof of the pre-treatment section may be refractory lined as well.
  • the refractory can be of a thickness similar or different to that of other sections, to reduce heat loss caused by a high convection of the gas in this section.
  • This roof refractory preferably covers the whole top surface of the pre-treatment section except in the area where the buffer section leads into the pre-treatment section.
  • the roof refractory can be of a thickness similar or different to that of other sections.
  • the cross-sectional enlargement in the upper portion of the pre-treatment section and the narrowing in the lower portion of the pre-treatment section ensures that a cone-shaped discharge area (discharge cone) made of bulk material forms within the gas space of the section.
  • the discharge cone is supplied centrally with the feed materials from the buffer section.
  • Gas supply means e.g.
  • burners, nozzles, wall openings or other devices, enabling hot gases to be supplied to the bulk are also provided above the discharge cone, in a so-called annular space, via which hot gases (e.g. combustion gases, temporarily stored or recirculated excess gases or inert combustion gases) can be supplied to the discharge cone.
  • hot gases e.g. combustion gases, temporarily stored or recirculated excess gases or inert combustion gases
  • the surface of the discharge cone is thus shock-heated by the hot gases (to more than 800°C), whereby sticking of the feed materials with the refractory lining (e.g. brick lining or castable lining) may be sufficiently prevented.
  • Shock heating with temperatures of e.g. 800°C
  • of the surface can be achieved, for example, by means of burners directed radially at the bulk.
  • shock heating can also be achieved by means of a ringshaped channel in which a flame rotates. This rotation can be achieved constructively by blowing the hot gas tangentially to the discharge cone and burning it, preferably in the direction of the Coriolis force.
  • the flame may burn off any oxygen which flows from the buffer section and any gas which may flow back from the discharge area, thereby creating an overpressure and forcing the gas in the direction of the lower laying intermediate section and upper oxidation section.
  • the reactor requires no permanent nitrogen (N 2 ) blanketing, thus substantially reducing operating cost.
  • the plenum section also includes an intermediate section located below and adjacent to the pre-treatment section.
  • the heat from the pre-treatment section and the waste heat from the upper oxidation section located below the intermediate section are used for final drying, pyrolysis of the feed materials and preheating for the subsequent upper oxidation section.
  • the typical combustion/pyrolysis temperatures of the intermediate section lead to the formation of complex molecules, e.g. liquid tars/oils or organic gases/vapors.
  • the intermediate section may be designed such that the top of the reactor is shielded from the heat from the subsequent upper oxidation section, which may be more than 2000°C.
  • this section can be considerably less high, because the shielding function is ensured by the feed and buffer sections' design and construction materials.
  • the reactor may therefore be on the whole smaller or has a higher throughput at the same height, compared to a cupola-type reactor.
  • the intermediate section is refractory lined (e.g. brick lined or castable lined) within the steel shell, wherein the refractory can be of a thickness similar or different to that of other sections. This embodiment simplifies the commissioning (starting up) of the reactor, as high temperatures can also occur in the intermediate section during this time.
  • the intermediate section can either be cylindrical or extend downwards in cross-section.
  • the cylindrical structure is advantageous for the manufacture of the reactor, since a cylindrical intermediate section is easier to produce.
  • the cross-section of the intermediate section widens downwards, as e.g. the use of coal can cause the bulk volume to expand due to the heat rising from below.
  • the cross section is widened, it may be possible to prevent the coal from jamming.
  • an upper oxidation section is provided, wherein in the upper oxidation section tuyeres are arranged. Through the tuyeres untreated or preheated oxygen and/or air can be supplied to the bulk, which has moved into the upper oxidation section.
  • the tuyeres are arranged in at least two levels, at least one upper level (defined by the height or vertical distance from the reactor bottom) and one lower level (defined by the height or vertical distance from the reactor bottom, which is smaller than the vertical distance from the reactor bottom of the upper level). At least one tuyere is arranged per level.
  • At least two or more tuyeres are arranged per level, whereby these tuyeres may further be arranged all-round, preferably radially distributed, on each level. Since the tuyeres are arranged on at least two levels, it can be achieved that the upper oxidation section is considerably larger than the oxidation section of reactors, which have only one level with tuyeres. Due to the enlarged upper oxidation section, the throughput at the same diameter as well as the residence time of the feed materials can be increased compared to reactors which have only one level with tuyeres.
  • the arrangement of the tuyeres in at least two levels may be advantageous, because a better distribution of the gas may be achieved with uniform heating of the bulk. In addition, this may ensure that local overheating of the refractory lining (e.g. brick lining or castable lining) is avoided as far as possible.
  • the refractory lining e.g. brick lining or castable lining
  • the tuyeres (of the upper oxidation section and the conical lower oxidation section) are made of copper or steel. Furthermore, it may be provided that the tuyeres have a ceramic inner tube. This embodiment of the tuyeres (with a ceramic inner tube) enables the tuyere to be protected against melting of the metal by adding oxygen and/or air, whereby oxygen and/or air that can also be preheated (e.g. to temperatures > 500°C). It can also be advantageous that a compressible and temperature-resistant layer is arranged between the ceramic inner tube of the tuyere and the metal tuyere itself, whereby thermally induced mechanical stresses can be compensated. This compressible and temperature-resistant layer consists, for example, of high-temperature felt, high-temperature cardboard or high-temperature foam.
  • the tuyeres may be made of ceramic.
  • the oxidation section can be operated with a supply of hot air and/or oxygen having a temperature more than 1000°C and thus a bulk temperature of more than 2000°C, since ceramics can withstand higher temperatures than metals, which are usually water-cooled.
  • the inevitably necessary cooling of metallic tuyeres is not necessary for tuyeres made entirely of ceramics, whereby the heat loss can be reduced by more than 5 %.
  • the chemical load caused by melting without cooling and the high thermal stress can be achieved for these tuyeres by a combination of ceramics with good thermal conductivity (e.g. silicon carbide with e.g. 85 W/(m ⁇ K)) and slag freezing, followed by insulating ceramics (e.g. Spinel Corundum with less than 4 W/(m ⁇ K)).
  • the tuyeres made of metal or ceramic are arranged on at least two levels.
  • the temperature in the oxidation section is increased to such an extent that all substances are converted into inorganic gas, such as carbon monoxide (CO), hydrogen (H 2 ), water (H 2 O), carbon dioxide (CO 2 ), hydrogen sulphide (H 2 S), ammonia (NH 3 ), nitrogen dioxide (NO 2 ) or sulphur dioxide (SO 2 ), liquid metal or liquid slag, coke or carbon (C).
  • the temperature can be, for example, about 1500°C to 1800°C at the edge area of the upper oxidation section, and may be above 2000°C to 3000°C in the center of the bulk.
  • the upper oxidation section comprises a refractory lining (e.g. brick lining or castable lining) within the steel shell, wherein the refractory can be of a thickness similar or different to that of other sections.
  • a refractory lining e.g. brick lining or castable lining
  • the upper oxidation section can either be cylindrical or tapered towards the bottom.
  • the cylindrical structure is advantageous for the manufacture of the reactor, as a cylindrical upper oxidation section is easier to produce. It can also be advantageous, however, if the cross-section in the top section of the upper oxidation section is wider than the cylindrical design and narrows downwards until the cross-section of the cylindrical design is realized.
  • This design enables the structure to follow the reduction of the bulk volume turning into gas, having a smaller cross-section at the bottom of the upper oxidation section.
  • This design allows that the oxygen may better reach the middle of the bulk, thereby avoiding zones of partially untreated material in the center (so called "dead man"). Due to the possible larger diameter at the top of the upper oxidation section, a capacity increase of over 30% per meter height of the upper oxidation section is feasible.
  • an upper reduction section is arranged in the co-current section, into which essentially no organic components enter.
  • the upper reduction section has a cross-sectional enlargement compared to the upper oxidation section, which changes the sinking rate of the then essentially completely carbonized bulk and increases the residence time (compared to a reactor of the same height).
  • the upper reduction section comprises a refractory lining (e.g. brick lining or castable lining) within the steel shell, wherein the refractory can be of a thickness similar or different to that of other sections.
  • the upper reduction section is designed such that the heat/thermal energy produced in the oxidation section is turned into chemical energy (e.g.
  • the gas flows through the carbonized bulk in co-current and thermal energy is converted into chemical energy.
  • carbon dioxide (CO 2 ) is converted into carbon monoxide (CO) and water (H 2 O) into hydrogen (H 2 ) and carbon monoxide (CO), whereby the carbon still contained in the bulk is further gasified.
  • the gases are simultaneously cooled (by the endothermic reaction), for example to temperatures between approx. 800 °C (e.g. complete conversion to H 2 ) and approx. 1500 °C, wherein at a temperature of above 1000 °C a complete conversion to CO takes place.
  • the upper reduction section By the free choice of height and diameter of the upper reduction section, different residence times can be realized. The longer the residence time at sufficient heat, the more H 2 and CO can be formed. Furthermore, the upper reduction section can be designed such that cooling can take place in such a way that standard refractory lining materials, such as e.g. Alumina-, Spinel- or Chrome-corundum, can be used.
  • standard refractory lining materials such as e.g. Alumina-, Spinel- or Chrome-corundum
  • At least one additional tuyere for steam or water injection may be arranged in the upper reduction section.
  • the arrangement of at least one additional tuyere for steam or water injection may provide the advantage that steam or water may be injected into the upper reduction section.
  • the gas As the gas leaving the upper reduction section in co-current and also the gas leaving the below arranged countercurrent section in countercurrent, the gas would have a high gas velocity and thus entrain a lot of dust, rendering economic gas cleaning unlikely.
  • the cross-sectional area of the gas outlet section is larger than the cross-sectional area of the upper reduction section.
  • a cone-shaped bulk can form. Due to the greatly increased surface area of the cone-shaped bulk, the gas may flow off at a significantly reduced speed (e.g. at 0.5 m/s) and the dust entrainment may be reduced to such an extent that standard dust separators (e.g. cyclone, bag filter) can economically separate the remaining dust.
  • standard dust separators e.g. cyclone, bag filter
  • the gas outlet section comprises at least one gas outlet.
  • This at least one gas outlet may be arranged in the gas outlet section in such a way that the gas can either escape at an upward angle, horizontal or that the gas is discharged downwards. It is also conceivable that several (e.g. four) gas outlets are arranged all-round, preferably distributed evenly around the circumference.
  • the gas coming from the upper reduction section the gas coming from the bottom (from the lower conical reduction section and the lower conical oxidation section) also flows through the gas outlet section.
  • the last reaction water gas shift reaction, H2O+CO ⁇ H2+CO2 takes place in the gas chamber above the cone-shaped bulk, in order to then leave the reactor.
  • the gas outlet section is preferably refractory lined within the surrounding steel shell.
  • the refractory can be of a thickness similar or different to that of other sections. It may be also preferable that a refractory is arranged at the top of the gas outlet section. This top refractory preferably covers the whole top surface of the gas outlet section except in the area where the upper reduction section leads into the gas outlet section.
  • the top refractory can be of a thickness similar or different to that of other sections.
  • the gas outlet section comprises at least one tuyere for steam or water injection.
  • a post-gasification section is realized within the gas outlet section.
  • the tuyere may supply the injected steam or water into the cone-shaped bulk or into the gas space above the cone-shaped bulk.
  • the hydrogen output of the reactor may thus be increased by a minimum of 8%. This may be achieved without any changes in reactor's dimensions. Even after converting the hereby reduced amount of CO in downstream watergas-shift reactors to additional hydrogen, the increase of the hydrogen output of the whole plant may be increased by a minimum of 2%.
  • the conical countercurrent section is preferably refractory lined within a surrounding steel shell.
  • the conical countercurrent section comprises a conical lower reduction section to convert the thermal energy of the gas from the conical lower oxidation section into chemical energy (mainly CO) and to generate the gas flow upwards in countercurrent to the bulk moving downwards.
  • This conical lower reduction section for which the cut-off tip of the cone of the conical lower reduction section points downwards, is located below the gas outlet section.
  • At least one additional tuyere for steam or water injection may be arranged in the conical lower reduction section.
  • the arrangement of at least one additional tuyere for steam or water injection may provide the advantage that steam or water may be injected into the conical lower reduction section.
  • the bulk of residual carbonized material (which has not yet been converted into gas), slag and metals can also be arranged in the form of a double truncated cone.
  • the upper truncated cone projects into the gas outlet section and the lower truncated cone is arranged in the conical lower reduction section and the conical lower oxidation section.
  • a conical lower oxidation section is arranged with the cut tip of the cone pointing downwards.
  • the residual carbonized material is converted into gas.
  • at least one tuyere consisting of metal or ceramic, as previously described for the upper oxidation section, is arranged in at least one level, via which untreated or preheated oxygen and/or air can be supplied to the molten metal and slag.
  • the resulting gas then flows in the direction of the gas outlet section via the conical lower reduction section, this time in countercurrent to the bulk moving downwards towards the reactor bottom. Since all material was previously forced through the upper oxidation section, all materials in the lower conical oxidation section are inorganic (hence no Seveso toxins, tars, oils, organic components, plastics, and so on remain). The gas flowing to the gas outlet section is therefore not contaminated by this countercurrent gas. Further, the temperature can be adjusted (e.g. to temperatures > 500°C) in such a way that the molten slag and the molten metals can emerge in liquid form via at least one tapping, for collection and discharge. Metal and slag, for example, can be collected in coquille moulds.
  • a continuous granulation (liquid or dry) with subsequent separation of metal and slag is carried out via e.g. a magnetic separator.
  • a magnetic separator it is conceivable that two separate tappings (as for a furnace) are provided so that metal and slag can drain off separately.
  • the excessive thermal energy in the lower conical reduction section (as previously described for the upper reduction zone) is converted into usable chemical energy.
  • Carbon dioxide (CO 2 ) is converted to carbon monoxide (CO) on the hot carbonized material (C), water (H 2 O) to hydrogen (H 2 ) and carbon monoxide (CO).
  • the gas can also cool to over 1000°C (complete conversion to CO) and to about 800°C (complete conversion to H 2 ).
  • the gas may be cooled to about 650°C to 750°C for an optimal water gas shift reaction, as the steam and water is injected into the gas outlet section.
  • the reactor has both, a lower reduction section in the countercurrent section and an upper reduction section in the co-current section
  • the total reduction section volume (sum of the volumes of the upper and conical lower reduction sections) can be considerably larger than the usually one reduction section of known reactors.
  • EP 1 261 827 B1 in which only one reduction section is arranged in the area of the gas outlet section.
  • the increased volume for the lower conical reduction section is achieved by the cone design of the countercurrent section (whereby the cone has an angle of approx. 60° from a hypothetical horizontal axis). For all subsequent angles it is intended that an angle of 0 ° corresponds to a hypothetical horizontal and an angle of 90 ° corresponds to a right angle (starting from a hypothetical horizontal).
  • the cone design also ensures that the slag can drain off without freezing and/or excessive wear on the refractory.
  • the reactor has two reduction sections, namely an upper reduction section in the co-current section and a conical lower reduction section in the countercurrent section, considerably more thermal energy can be converted into chemical energy, in the form of more hydrogen (H 2 ) or carbon monoxide (CO). Further, as at least one tuyere for steam or water injection is arranged in the gas outlet section even more thermal energy can be converted into chemical energy in the form of more hydrogen (H2).
  • the injection of steam or water provides a post-gasification section within the gas outlet section. In this post-gasification section, the hydrogen output of the reactor may thus be increased by a minimum of 8% without any changes in reactor's dimensions.
  • At least one further tuyere for steam or water injection may be arranged in the conical lower reduction section and/or and at least one additional tuyere for steam or water injection may be arranged in the upper reduction section, thereby the conversion of carbon (C) and water (H2O) to hydrogen (H2) and carbon monoxide (CO) is increased, the gas temperature is lowered, without reducing the formation of carbon monoxide (CO) from carbon (C) and carbon dioxide (CO2).
  • a further advantage may be that the arrangement of the upper reduction section in the co-current section may provide that considerably lower temperatures can be achieved in the gas outlet.
  • the reactor achieves a simple, inexpensive and environmentally friendly material and/or energetic utilization of feed materials while simultaneously improving the production of hydrogen.
  • a capacity increase is made possible by employing the reactor described herein.
  • an upper auto-thermal section is located below the upper oxidation section comprising at least one tuyere through which steam and/or non-solid fuels, in particular natural gas, LPG or crude oil, is suppliable and/or an auto-thermal section is located below the conical lower reduction section comprising at least one tuyere through which steam and/or non-solid fuels, in particular natural gas, LPG or crude oil, is also suppliable.
  • the amount of the reactor's hydrogen leaving the reactor may at least be double , without any changes in its dimensions. This effect and the effect of the post-gasification section are cumulative.
  • the upper auto-thermal section is located in the cross-sectional enlargement of the upper reduction section.
  • the reactor according to claim 6 also comprises an upper co-current section, a central gas outlet section and a lower countercurrent section.
  • the gas flows downwards to the gas outlet section.
  • the gas flows from below the gas outlet section to the gas outlet section. The gas escapes via at least one gas outlet in the gas outlet section.
  • the reactor according to claim 6 is essentially the same reactor as described for the reactor according to claim 1, however, the reactor according to claim 6 does not necessarily comprises at least one tuyere for steam and water injection in the gas outlet section, but comprises an upper auto-thermal section located below the upper oxidation section comprising at least one tuyere through which steam and/or non-solid fuels, in particular natural gas, LPG or crude oil, is suppliable.
  • the reactor according to claim 6 comprises an upper auto-thermal section, which is located below the upper oxidation section and above the upper reduction section.
  • the upper auto-thermal section comprises at least one tuyere through which steam and/or non-solid fuels, in particular natural gas, LPG or crude oil, can be supplied to the bulk, which has moved out of the upper oxidation section.
  • the upper auto-thermal section may be located in that portion of the upper reduction section that has a cross-sectional enlargement compared to the upper oxidation section. The increased diameter of the upper reduction section reduces gas speed and thus avoids a high pressure drop.
  • the overall production of hydrogen and carbon monoxide may be increased.
  • the upper auto-thermal section there is a high consumption of oxygen. That is why the upper auto-thermal section is located below the upper oxidation section or on the bottom of the upper oxidation section within the upper oxidation section.
  • the reactor according to claim 6 further comprises a lower auto-thermal section, which is located below the conical lower reduction section.
  • the lower auto-thermal section comprises at least one tuyere through which steam and non-solid fuels, in particular natural gas, LPG or crude oil, can be supplied to the bulk, here the molten metal, molten slag and rcoked feed material.
  • the reactor comprises only one auto-thermal section, either the upper auto-thermal section or the lower auto-thermal section.
  • the reactor comprising an upper auto-thermal and/or lower auto-thermal section further comprises that the gas outlet section comprises a post-gasification section comprising at least one tuyere for steam or water injection.
  • the gas outlet section comprises a post-gasification section comprising at least one tuyere for steam or water injection.
  • the upper reduction section is arranged above the gas outlet section, wherein the gas outlet section adjoins the lower part of the upper reduction section by creating a cross-sectional enlargement.
  • the cross-sectional enlargement is abrupt/discrete.
  • the cross-sectional area of the gas outlet section increases by at least twice that of the cross-sectional area of the upper reduction section.
  • This embodiment ensures that the bulk widens conically, thereby increasing the surface area or discharge area of the bulk.
  • the surface or discharge area of the bulk essentially corresponds to the outer surface for a truncated cone-shaped design.
  • any one of the above-described reactors provides that the cross-sectional enlargement is such that the discharge area of the bulk is at least three times larger than the cross-sectional area of the upper reduction section. Furthermore, the cross-sectional enlargement can be so large that the discharge area of the bulk is at least seven times or even at least nine times larger than the cross-sectional area of the upper reduction section.
  • the cross-sectional enlargement of the gas outlet section is such that the discharge area of the bulk is increased by at least five times the cross-sectional area of the upper oxidation section. Furthermore, the cross-sectional enlargement can be so large that the discharge area of the bulk is at least nine times larger than the cross-sectional area of the upper oxidation section.
  • a reduced dust entrainment is particularly advantageous in order to be able to carry out a subsequent gas cleaning or dust separation economically. Furthermore, this embodiment enables the dust (due to the small quantities) to be returned to the gasifier inlet without significantly reducing the capacity of the reactor for fresh feed material, eliminating the need to dispose hazardous dust waste.
  • the volume ratio of the upper oxidation section volume to the plenum section volume is a ratio of 1 : N volume units, wherein N is a number greater than or equal to ( ⁇ ) 4 and less than or equal to ( ⁇ ) 20.
  • the volume of the upper oxidation section is defined as the inner volume between the upper edge of the at least one tuyere of the upper level, the lower edge of the at least one tuyere of the lower level and the circumferential refractory lining.
  • the volume of the plenum section is defined as the inner volume between the sluice, the upper edge of the at least one tuyere of the upper level of the upper oxidation section and the circumferential lining.
  • the discharge cone area of the bulk in the conical lower reduction section is also enlarged, whereby gas with smaller gas flow velocities flows out of the bulk and less dust is entrained.
  • the angle of the conical lower reduction section and the angle of the conical lower oxidation section are between 50° and 70°. Due to this embodiment of above-described reactors, the slag, which is kept liquid at sufficiently high temperatures in the conical lower oxidation section and the conical lower reduction section, drains off better. It is envisioned that the walls run at an angle of approx. 50-90°, preferably approx. 60°. Due to this design, the wear of the refractory and thus the maintenance may be reduced further, therefore allowing a longer uptime.
  • the inner cross-sectional area of the intermediate section is cylindrically constant or is tapered (widens) in the direction of the reactor floor
  • the inner cross-sectional area of the upper oxidation section is cylindrically constant or is tapered (narrows) in the direction of the reactor floor
  • the inner cross-sectional area of the upper reduction section is cylindrical constant or widens towards the bottom of the reactor, immediately following the upper oxidation section.
  • the cylindrical constant cross-sectional area is easier to produce.
  • a widening of the intermediate section prevents material jamming in the intermediate section, e.g. bulky materials like low quality coal waste, due to thermal expansion when the bulk moves down towards the upper oxidation section.
  • a narrowing of the upper oxidation zone allows the inner surface to follow the reduction of the bulk while the volume turns into gas, having a smaller diameter at the bottom of the oxidation section and thus allows the oxygen to better reach the middle of the bulk, thereby avoiding zones of partially untreated material in the center ("dead man"). Due to the described possible larger diameter at the top of the oxidation zone, this allows a capacity increase of over 30% per meter height of the upper oxidation section.
  • a cross-sectional enlargement or narrowing may be also advantageous, as to smoothly expand from the diameter of the upper oxidation section to the diameter of the upper reduction section. This way, the cross-section can be enlarged which results in the high retention time and better CO/H 2 content, but without risking the formation of a gas pocket, not allowing incompletely reacted gas components to reach the gas outlet via a short circuit.
  • the inner cross-sectional area of the intermediate section and the inner cross-sectional area of the upper oxidation section are cylindrically constant.
  • the inner cross-sectional area of the intermediate section widens in the direction of the reactor floor, thereby increasing the cross-sectional area for reasons described above and the subsequent inner cross-sectional area of the upper oxidation section narrows in the direction of the reactor floor, thereby increasing the cross-sectional area for reasons described above.
  • At least one further tuyere is arranged on a level of the conical lower reduction section.
  • the further tuyere additionally supplies air and/or oxygen in such a defined way, so that almost no CO 2 is produced, but almost exclusively CO. Furthermore, it can be achieved through this embodiment that the throughput can be increased.
  • a further embodiment of any one of the above-described reactors provides that at least one other tuyere is arranged on a further level (height) of the conical lower oxidation section. This tuyere may preferably be located above the tapping.
  • the tuyere above the tapping By arranging the tuyere above the tapping, a more efficient melting can be facilitated in the area of the tapping, as the heat is generated in the area where the melt is to run off liquid. At the same time, the arrangement of the tuyere above the tapping ensures that the solidified melt desired on the opposite side of the tapping (so-called slag freezing, which protects the refractory lining, e.g. brick lining) is not liquefied and therefore does not flow off.
  • slag freezing which protects the refractory lining, e.g. brick lining
  • This embodiment may allow a simpler arrangement of the gas cleaning stages and/or lower equipment costs, as for example only one steam generator is connected to the single gas outlet, instead of several.
  • the gas outlets or the only one gas outlet is arranged in the gas outlet section with an upward angle of 30° to 90°, usually approx. 60°. This may ensure that liquid slag droplets or dust particles flow back into the reactor, instead of accumulating and possibly plugging the gas outlets. It further may be achieved that more dust may be retained inside the reactor due to gravity separation.
  • the gas outlet can also be angled downwards, between -60° and 0°.
  • due to the downward angle dust and slag may end up in the downstream equipment.
  • this embodiment may be beneficial if the geometry is not constructible due to restriction from the construction site or special downstream equipment.
  • a further embodiment of any one of the above-described reactors according to the invention provides that a heat exchanger and/or a steam generator is coupled downstream to the gas outlet section and gas suction means (e.g. at least one explosion-protected high-temperature blower) are coupled downstream to the heat exchanger or steam generator.
  • gas suction means e.g. at least one explosion-protected high-temperature blower
  • any one of the above-described reactors can also be run or operated at overpressure.
  • high-temperature gate valves are arranged in the surrounding shell of the upper oxidation section and/or the conical lower oxidation section, the high-temperature gate valves being designed to allow the tuyeres to be replaced during full operation of the reactor.
  • the high-temperature gate valves are advantageous, since gas can escape from the reactor when the tuyeres are exchanged during overpressure operation. It is therefore advantageous that the tuyeres are first pulled behind a high-temperature packing gland, whereby at this moment the tuyeres are still in an outer tube and are sealed in this tube by the gland. In the event that the tuyere is to be pulled or replaced, the high temperature gate valve is closed and the tuyere can be pulled completely. The installation of the new or repaired tuyeres can then be carried out by insertion, whereby the gate valve is opened and the tuyere is pushed partially into the packing gland. Hence, the valve can be safely opened and the tuyere can be inserted fully and fixed/secured.
  • the high-temperature gate valves are either ceramic, heat-resistant, cooled or a combination of the above features.
  • the overpressure increases the density of the gas, thus reducing the volume flow from the reactor and further reduces the size and cost of the downstream equipment.
  • the above-mentioned tasks of the invention are also solved by the methods specified in claims 4 to 5 or in claim 8.
  • the methods can be performed using above-described reactors for the improved production of hydrogen and for gasifying, cracking and/or melting of feed materials.
  • This is advantageously suited, among other things, for the material and/or energetic recycling of feed materials and waste, e.g. waste materials, such as used tires, hazardous waste, asbestos waste, toxic hospital waste, industrial waste, electronic waste, coal and/or coal dust, non-recyclable plastic, wood or paper, light/coarse ASR (automotive shredder residues) and/or MSW (municipal solid waste) or the like.
  • waste materials such as used tires, hazardous waste, asbestos waste, toxic hospital waste, industrial waste, electronic waste, coal and/or coal dust, non-recyclable plastic, wood or paper, light/coarse ASR (automotive shredder residues) and/or MSW (municipal solid waste) or the like.
  • the method steps in accordance with the invention using a reactor according to the claims 1 to 3 initially include providing feed materials into the co-current section, whereby the feed materials are introduced via the feed section with a sluice.
  • the feed materials are preheated and pre-dried and then reach the pre-treatment section, wherein the cross-section of the pre-treatment section is enlarged with respect to the buffer section, where the feed materials form a discharge bulk having a discharge cone.
  • the surface of the bulk is heated in the pre-treatment section to at least 800°C at its surface by supplying oxygen and/or air and/or combustion gases or by supplying preheated oxygen and/or air or combustion gas, which are supplied via gas supply means (e.g. burners and/or nozzles), which open in the pre-treatment section in the region of the cross-sectional enlargement of the pre-treatment section, in order to trigger at least partial pyrolysis on the surface of the feed materials.
  • gas supply means e.g. burners and/or nozzles
  • the feed materials are fully pyrolyzed and fully dried.
  • a hot upper oxidation section is created, which is located below the intermediate section.
  • the pyrolysis products and parts of the feed materials burn, crack and/or melt in this hot upper oxidation section, whereupon further coking of the not yet converted feed materials takes place.
  • thermal energy is then converted into chemical energy.
  • the gas flows in the co-current section from the feed section to the gas outlet in co-current.
  • a post-gasification section is created within the gas outlet section.
  • carbon of the coked feed material is converted into hydrogen and carbon monoxide, thereby lowering the gas exit temperatures to temperatures between 400°C and 750°C.
  • a hot section is also created in the conical lower oxidation section by supplying untreated or preheated oxygen and/or air through the at least one tuyere of the conical lower oxidation section.
  • Molten metal and molten slag are also collected in this lower-arranged hot lower oxidation section. These molten metal and/or molten slag are tapped off via at least one tapping (e.g. in molds) or run out continuously (e.g. to a slag granulation) as required.
  • gases are also generated which flow upwards (in countercurrent) in the direction of the gas outlet.
  • the gases from the co-current section (from top to bottom), the gases from the countercurrent section (from bottom to top) and the gases from the post-gasification section within the gas outlet section are discharged from the gas outlet section through the at least one gas outlet.
  • the method steps may further comprise supplying steam or water through the at least one tuyere for steam or water injection of the conical lower reduction section and/or through the at least one tuyere for steam or water injection of the upper reduction section.
  • the method steps in accordance with the invention using a reactor according to the claim 6 initially include providing feed materials into the co-current section, whereby the feed materials are introduced via the feed section with a sluice.
  • the feed materials are preheated and pre-dried and then reach the pre-treatment section, wherein the cross-section of the pre-treatment section is enlarged with respect to the buffer section, where the feed materials form a discharge bulk having a discharge cone.
  • the surface of the bulk is heated in the pre-treatment section to at least 800°C at its surface by supplying oxygen and/or air and/or combustion gases or by supplying preheated oxygen and/or air or combustion gas, which are supplied via gas supply means (e.g. burners and/or nozzles), which open in the pre-treatment section in the region of the cross-sectional enlargement of the pre-treatment section, in order to trigger at least partial pyrolysis on the surface of the feed materials.
  • gas supply means e.g. burners and/or nozzles
  • the feed materials are fully pyrolyzed and fully dried.
  • a hot upper oxidation section is created, which is located below the intermediate section.
  • the pyrolysis products and parts of the feed materials burn, crack and/or melt in this hot upper oxidation section, whereupon further coking of the not yet converted feed materials takes place.
  • an upper auto-thermal section is created, which is located below the upper oxidation section.
  • the non-solid fuels may react with oxygen to CO2 and H2O (exothermal) and after with steam to H2 and CO (endothermal).
  • thermal energy is then converted into chemical energy.
  • the gas flows in the co-current section from the feed section to the gas outlet in co-current.
  • a hot section is also created in the conical lower oxidation section by supplying untreated or preheated oxygen and/or air through the at least one tuyere of the conical lower oxidation section.
  • Molten metal and molten slag are also collected in this lower-arranged hot lower oxidation section. These molten metal and/or molten slag are tapped off via at least one tapping (e.g. in molds) or run out continuously (e.g. to a slag granulation) as required.
  • gases are also generated which flow upwards (in countercurrent) in the direction of the gas outlet.
  • the gases from the co-current section (from top to bottom) and the gases from the countercurrent section (from bottom to top) are discharged from the gas outlet section through the at least one gas outlet.
  • the method further comprises the step of converting thermal energy of the gas from the lower oxidation section into chemical energy in the lower auto-thermal section by injecting steam or non-solid fuels, in particular natural gas, LPG or crude oil, through the at least one tuyere of the auto-thermal section located above the lower oxidation section and below the lower reduction section.
  • steam or non-solid fuels in particular natural gas, LPG or crude oil
  • the non-solid fuels react with oxygen to CO2 and H2O (exothermal) and after with steam to H2 and CO (endothermal).
  • This endothermal and exothermal reaction at constant temperature ensures that the gas will not change its temperature before reaching the lower reduction section.
  • the method steps essential for the invention using any of the above-described reactors can be advantageously further comprise exhausting the gases produced in the co-current section and the gases produced in the countercurrent section by suction.
  • gas suction means are used.
  • the suction creates a negative pressure in the reactor.
  • the use of negative pressure in the reactor allows maintenance of the reactor during operation, as air can be sucked in when the reactor is opened, but no gas can escape.
  • an overpressure may be generated in the reactor, whereby the gases produced in the reactor are discharged by overpressure.
  • the reactor forces the hot gas into the subsequent process steps.
  • This embodiment eliminates the need for an explosion-protected high-temperature suction blower.
  • higher pressures up to 10 bar overpressure which are possible in the reactor according to the invention, allow the volume of the escaping gas to be reduced, whereby smaller apparatuses can be used for gas purification.
  • the operation with positive pressure is advantageous in that the gas is forced out of the reactor.
  • the pressure in the reactor is created by the resulting gas, the thermal expansion of the gas and the supply of the gaseous media with excess pressure.
  • the at least one sluice for the feeding of the feed materials can be opened or closed without any problems. This can be solved constructively for example, with hydraulically operated hatches (doors).
  • the hatches are arranged in such a way that in the event of desired or accidental overpressure in the reactor, the hatches are additionally pressed closed and no gas can escape unintentionally. It may also be advantageous that the sluices have additional pressure equalization lines to the atmosphere and/or to a safe area inside the reactor. Accordingly, the hatches can also be opened at the any desired overpressure in the reactor because the hatches drive does not have to work against a pressure difference.
  • inert gases like nitrogen (N2) or carbon dioxide (CO 2 ) are injected to start up the reactor.
  • the reactor for gasifying and/or melting of feed materials can be used for the recovery of energy.
  • feed materials such as waste materials, such as used tires, hazardous waste, asbestos waste, toxic hospital waste, industrial waste, electronic waste, coal and/or coal dust, non-recyclable plastic, wood or paper, light/coarse ASR (automotive shredder residues) and/or MSW (municipal solid waste) or the like, may be fed to the reactor and its internal energy is gained in form of gas, which contains chemical and thermal energy, which may be used to generate electricity (waste-to-energy).
  • waste materials such as used tires, hazardous waste, asbestos waste, toxic hospital waste, industrial waste, electronic waste, coal and/or coal dust, non-recyclable plastic, wood or paper, light/coarse ASR (automotive shredder residues) and/or MSW (municipal solid waste) or the like
  • ASR automotive shredder residues
  • MSW munal solid waste
  • a system comprising a reactor according to claim 1 or claim 7 and a steam generator.
  • the steam generator comprises means which are connected to at least one tuyeres for steam or water injection, the tuyeres for steam or water injection being located in the gas outlet section.
  • a system comprising a reactor according to claim 3 or claim 6 and a gas storage tank and/or a gas pipeline.
  • the gas storage tank and/or a gas pipeline comprises means which are connected to at least one tuyeres through which steam and/or non-solid fuels, in particular natural gas, LPG or crude oil, is suppliable, the at least one tuyeres being located in the upper auto-thermal section and/or the lower arranged auto-thermal section.
  • feed materials modifications of the reactor and/or method may be useful.
  • different feed materials can also be combined, for example by adding feed materials with a higher energy value (e.g. non-recyclable plastic, contaminated waste wood, car tires, or the like) during the gasifying/cracking/melting of non-organic feed materials.
  • feed materials with a higher energy value e.g. non-recyclable plastic, contaminated waste wood, car tires, or the like
  • the reactor 100 shown in Figure 1 has three major sections, which are a co-current section 110, a gas outlet section 120 and a countercurrent section 130.
  • the co-current section 110, the gas outlet section 120 and the countercurrent section 130 are surrounded by an, e.g., steel shell, which of obvious necessity has recesses for means for feeding feed materials and gases as well as discharging gases and materials.
  • the co-current section 110, the gas outlet section 120 and the countercurrent section 130 are arranged substantially concentrically to each other (represented by the vertical dash-dot line passing substantially through the center of the reactor).
  • a plenum section 111, an upper oxidation section 116 and an upper reduction section 118 are arranged in the co-current section.
  • the plenum section 111 comprises a feed section with a sluice 112, whereby feed materials such as waste, water, car tires, additives or other feed materials are fed into the reactor from above via the feed section.
  • feed materials such as waste, water, car tires, additives or other feed materials are fed into the reactor from above via the feed section.
  • the material flow of the solids is shown as a dashed arrow from top to bottom.
  • a buffer section 113 is arranged below the feed section with a sluice 112.
  • a pre-treatment section 114 for buffering and pre-drying the feed material volume is arranged below the buffer section, thereby creating a cross-sectional enlargement in the upper area and a narrowing cross-section in the bottom area so that a discharge cone (140) of the feed material can form from feed materials (indicated by the oblique dashed lines; between 114 and 119).
  • the bottom area corresponds to an inverted truncated cone with an angle ⁇ , wherein ⁇ is advantageously between 120° and 150°, preferably 135°.
  • two gas supply means 119 open in the pre-treatment section 114 in the region of the cross-sectional enlargement.
  • the pre-treatment section 114 can also be made inert by burning off all oxygen stoichiometrically (as lambda may be approximately 1), e.g. controlled by a low-cost paramagnetic or chemical oxygen-analyzer. Hence, the expensive nitrogen-blanketing, as needed for other reactors may be avoided.
  • An essentially cylindrical oxidation section 116 adjoins the intermediate section 115, wherein in the upper oxidation section 116 the tuyeres 117 are arranged circumferentially in a plurality of levels (here three levels as shown).
  • the reactor 100 shown in Fig. 1 may comprise an intermediate section 115 for which the inner cross-sectional area widens (see angle ⁇ , wherein ⁇ may be between 80° and 90°, approximately 87°) in the direction of the reactor floor and the inner cross-sectional area of the upper oxidation section 116 may taper/narrow (see angle ⁇ , wherein ⁇ may be between 80° and 90°, approximately 85°) in the direction of the reactor floor.
  • the cross-sectional area of upper reduction section 118 may expand (see angle ⁇ , wherein ⁇ is between 50° and 70°, approximately 60°) directly below the oxidation section 116.
  • Untreated and/or preheated oxygen and/or air is added via the tuyeres 117, which increases the temperature to such an extent that all substances are converted into inorganic gas, liquid metal, coke, carbon and/or mineral slag.
  • the upper reduction section 118 which adjoins the upper oxidation section 116 and which is arranged substantially above a subsequent gas outlet section 120, the endothermic conversion of thermal energy into chemical energy takes place.
  • the gas flowing co-current with the solids (represented by a dotted arrow running from top to bottom), is generated starting from the plenum section via to the upper oxidation section and the upper reduction section 118 from top to bottom, and then introduced into the gas outlet section 120.
  • At least one additional tuyere 139 for steam or water injection may be arranged in the upper reduction section 118.
  • the gas outlet section 120 is connected to the upper reduction section 118, thereby creating a cross-sectional enlargement. As the cross-sectional area of the gas outlet section 120 is larger than the cross-sectional area of the upper reduction section 118, a cone-shaped bulk 141 can form.
  • a post-gasification section 150 is located in the gas outlet section, the post-gasification section 150 comprising at least one tuyere 151 for steam or water injection.
  • the gas produced is - approximately in cross-flow to the cone-shaped bulk 141 - discharged in the gas outlet section 120 through at least one gas outlet 121 (shown by a dotted arrow running from left to right). It may be provided, for example, that four or more gas outlets 121 are distributed around the circumference (not shown), so that the gas produced in the co-current section and in the countercurrent section can be diverted radially in the cross-flow.
  • the gas outlet 121 can be designed in such a way that the gas can flow downwards.
  • the angle ⁇ of the gas outlet is downwards between -60° and 0° (horizontal). Indicated in Fig. 1 is an angle with -30°.
  • the gas outlet can also be designed in such a way that the gas is discharged upwards, with an angle ⁇ of the gas outlet being in particular 60°.
  • ⁇ of the gas outlet
  • any angle between -60° (sloped down), 0° (horizontal) and +90° (straight up vertically) can be designed.
  • the countercurrent section 130 comprising the conical lower reduction section 138 and the conical lower oxidation section 136.
  • the countercurrent section 130 is conical and tapered (narrows) towards the bottom of the reactor with an angle ⁇ , the angle ⁇ being between 50° and 90°, here approximately 60°.
  • the conical lower reduction section 138 the conversion of thermal energy into chemical energy also takes place.
  • At least one further tuyere 139 for steam or water injection may be arranged in the conical lower reduction section 138.
  • a conical lower oxidation section 136 in which at least one tuyere 137 and at least one tapping 131 are arranged.
  • air and/or oxygen is introduced in order to oxidize the remaining carbonized material and to prevent the molten metal and molten slag from solidifying.
  • the collection and discharge of molten metal and molten slag takes place in at least one tapping 131.
  • the gas generated in the conical lower oxidation section 136 and in the conical lower reduction section 138 also flows in countercurrent with the solid's flow through the bulk (represented by a dotted arrow running from bottom to top) to the gas outlet section 120, where it is discharged via the at least one gas outlet 121.
  • the reactor of Fig. 1 may have a volume ratio of the upper oxidation section volume to the plenum section volume can be a ratio of 1 : N volume units, wherein N is a number greater than or equal to ( ⁇ ) 4 and less than or equal to ( ⁇ ) 20.
  • the gases produced in the gas outlet section 120, the co-current section 110 and in the countercurrent section 130 are discharged by suction. Furthermore, it can be advantageously provided that an overpressure is generated in the co-current section 110, whereby the gases produced in the co-current section 110 are discharged by overpressure.
  • the reactor 100 shown in Figure 2 has three major sections, which are a co-current section 110, a gas outlet section 120 and a countercurrent section 130.
  • the co-current section 110, the gas outlet section 120 and the countercurrent section 130 are surrounded by a, e.g. steel shell, which of obvious necessity has recesses for means for feeding feed materials and gases as well as discharging gases and materials.
  • the co-current section 110, the gas outlet section 120 and the countercurrent section 130 are arranged substantially concentrically to each other (represented by the vertical dash-dot line passing substantially through the center of the reactor).
  • a plenum section 111, an upper oxidation section 116, an upper auto-thermal section and an upper reduction section 118 are arranged in the co-current section.
  • the plenum section 111 comprises a feed section with a sluice 112, whereby feed materials such as waste, water, car tires, additives or other feed materials are fed into the reactor from above via the feed section.
  • feed materials such as waste, water, car tires, additives or other feed materials are fed into the reactor from above via the feed section.
  • the material flow of the solids is shown as a dashed arrow from top to bottom.
  • a buffer section 113 is arranged below the feed section with a sluice 112.
  • a pre-treatment section 114 for buffering and pre-drying the feed material volume is arranged below the buffer section, thereby creating a cross-sectional enlargement in the upper area and a narrowing cross-section in the bottom area so that a discharge cone (140) of the feed material can form from feed materials (indicated by the oblique dashed lines; between 114 and 119).
  • the bottom area corresponds to an inverted truncated cone with an angle ⁇ , wherein ⁇ is advantageously between 120° and 150°, preferably 135°.
  • two gas supply means 119 may open in the pre-treatment section 114 in the region of the cross-sectional enlargement.
  • the pre-treatment section 114 can also be made inert by burning off all oxygen stoichiometrically (as lambda may be approximately 1), e.g. controlled by a low-cost paramagnetic or chemical oxygen-analyzer. Hence, the expensive nitrogen-blanketing, as needed for other reactors may be avoided.
  • An essentially cylindrical oxidation section 116 adjoins the intermediate section 115, wherein in the upper oxidation section 116 the tuyeres 117 are arranged circumferentially in a plurality of levels (here three levels as shown). Untreated and/or preheated oxygen and/or air is added via the tuyeres 117, which increases the temperature to such an extent that all substances are converted into inorganic gas, liquid metal, coke, carbon and/or mineral slag.
  • the upper oxidation section 116 comprises at least one tuyere 161 through which steam and/or non-solid fuels, in particular natural gas, LPG or crude oil, is suppliable.
  • the upper auto-thermal section 160 may be arranged in a cross-sectional enlargement of the reactor, located directly below the upper oxidation section 116.
  • the endothermic conversion of thermal energy into chemical energy takes place.
  • the gas flowing co-current with the solids (represented by a dotted arrow running from top to bottom), is generated starting from the plenum section via to the upper oxidation section and the upper reduction section 118 from top to bottom, and then introduced into the gas outlet section 120.
  • the gas outlet section 120 is connected to the upper reduction section 118, thereby creating a cross-sectional enlargement.
  • a cone-shaped bulk 141 can form.
  • the gas produced is - approximately in cross-flow to the cone-shaped bulk 141 - discharged in the gas outlet section 120 through at least one gas outlet 121 (shown by a dotted arrow running from left to right). It may be provided, for example, that four or more gas outlets 121 are distributed around the circumference (not shown), so that the gas produced in the co-current section and in the countercurrent section can be diverted radially in the cross-flow.
  • the gas outlet 121 can be designed in such a way that the gas can flow downwards.
  • the angle ⁇ of the gas outlet is downwards between -60° and 0° (horizontal). Indicated in Fig. 1 is an angle with -30°.
  • the gas outlet can also be designed in such a way that the gas is discharged upwards, with an angle ⁇ of the gas outlet being in particular 60°.
  • any angle between -60° (sloped down), 0° (horizontal) and +90° (straight up vertically) can be designed.
  • the countercurrent section 130 comprising the conical lower reduction section 138 and the conical lower oxidation section 136.
  • the countercurrent section 130 is conical and tapered (narrows) towards the bottom of the reactor with an angle ⁇ , the angle ⁇ being between 50° and 90°, here approximately 60°.
  • the conical lower reduction section 138 the conversion of thermal energy into chemical energy also takes place.
  • a conical lower oxidation section 136 in which at least one tuyere 137 and at least one tapping 131 are arranged.
  • air and/or oxygen is introduced in order to oxidize the remaining carbonized material and to prevent the molten metal and molten slag from solidifying.
  • the collection and discharge of molten metal and molten slag takes place in at least one tapping 131.
  • the gas generated in the conical lower oxidation section 136 and in the conical lower reduction section 138 also flows in countercurrent with the solid's flow through the bulk (represented by a dotted arrow running from bottom to top) to the gas outlet section 120, where it is discharged via the at least one gas outlet 121.
  • the reactor further comprises a lower auto-thermal section 162, which located below the conical lower reduction section 138, the lower auto-thermal section 162 comprising at least one tuyere 163 through which steam and non-solid fuels, in particular natural gas, LPG or crude oil, is suppliable.
  • a lower auto-thermal section 162 located below the conical lower reduction section 138, the lower auto-thermal section 162 comprising at least one tuyere 163 through which steam and non-solid fuels, in particular natural gas, LPG or crude oil, is suppliable.
  • the gas outlet section 120 further comprises a post-gasification section 150, as indicated in Fig. 1 , comprising at least one tuyere 151 for steam or water injection.
  • the reactors specifically described above is particularly suitable for the treatment (gasifying, cracking and/or melting) of wastes, it will be obvious to the skilled person in the art that modifications of the reactor are necessary or expedient when other feed materials are used.
  • the reactor described above can also be used to treat hazardous wastes or feed materials with higher metal contents, whereby the gasification/cracking principle and the melting principle will predominate in some cases.
  • Different feed materials can also be combined. For example, it is possible to add specific feed materials with a higher energy value (e.g. non-recyclable plastics, contaminated waste wood, tires, but also coal or the like) for melting non-organic feed materials.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Combustion & Propulsion (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Organic Chemistry (AREA)
  • Gasification And Melting Of Waste (AREA)
EP21150408.9A 2021-01-06 2021-01-06 Réacteur et procédé de gazéification et/ou de fusion de matières d'alimentation et de production d'hydrogène Withdrawn EP4026885A1 (fr)

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19816864A1 (de) * 1996-10-01 1999-10-07 Hans Ulrich Feustel Koksbeheizter Kreislaufgas-Kupolofen zur stofflichen und/oder energetischen Verwertung von Abfallmaterialien unterschiedlicher Zusammensetzung
WO2002046331A1 (fr) * 2000-12-04 2002-06-13 Emery Energy Company L.L.C. Gazeifieur a plusieurs facettes et procedes associes
EP1261827B1 (fr) 2000-02-17 2005-11-16 Maschinen- und Stahlbau GmbH Reacteur et procede de gazeification et/ou de fusion de matieres
EP3660132A1 (fr) * 2018-11-28 2020-06-03 Waste & Energy Solutions GmbH Réacteur et procédé de gazéification et/ou de fusion de matériaux d'alimentation
WO2020109425A1 (fr) * 2018-11-28 2020-06-04 Kbi Invest & Management Ag Réacteur et procédé de gazéification et/ou de fusion de matériaux de charge

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19816864A1 (de) * 1996-10-01 1999-10-07 Hans Ulrich Feustel Koksbeheizter Kreislaufgas-Kupolofen zur stofflichen und/oder energetischen Verwertung von Abfallmaterialien unterschiedlicher Zusammensetzung
EP1261827B1 (fr) 2000-02-17 2005-11-16 Maschinen- und Stahlbau GmbH Reacteur et procede de gazeification et/ou de fusion de matieres
WO2002046331A1 (fr) * 2000-12-04 2002-06-13 Emery Energy Company L.L.C. Gazeifieur a plusieurs facettes et procedes associes
EP3660132A1 (fr) * 2018-11-28 2020-06-03 Waste & Energy Solutions GmbH Réacteur et procédé de gazéification et/ou de fusion de matériaux d'alimentation
WO2020109425A1 (fr) * 2018-11-28 2020-06-04 Kbi Invest & Management Ag Réacteur et procédé de gazéification et/ou de fusion de matériaux de charge

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