JP2011513517A - Multi-zone carbon conversion system using plasma melting - Google Patents

Abstract

  A multi-zone carbon converter that converts processing raw materials into synthesis gas and slag, which uses plasma heat to dissolve ash into molten slag and / or keeps the slag in a molten state, carbon conversion in communication with the slag zone Consisting of a chamber containing zones. The carbon conversion zone and the slag zone are separated by an inter-zone region that acts as a barrier to limit or prevent mass transfer between the two zones. Acting on the plasma heat transfer from the slag zone, there may be an initial melting from ash to molten slag in the inter-zone region.

Description

  The present invention relates to gasification of a carbonaceous raw material, and particularly relates to a multi-zone type carbon conversion device.

Gasification is a process that allows carbonaceous raw materials such as municipal solid waste (MSW) and coal to be converted into combustible gases. The generated gas can be used for power generation and steam generation, and can also be used as a basic raw material for chemical products and liquid fuel.
Possible uses of this gas include: (B) Combustion with a boiler to generate water vapor, which is used for internal processing and other external uses and steam turbine power generation. (B) Direct combustion in a gas turbine or gas engine for power generation. (C) Fuel cell. (D) Production of methanol and other liquid fuels. (E) Raw materials for chemical products such as plastics and fertilizers. (F) Extract hydrogen and carbon monoxide and use them as industrial fuel gases. (G) Other industrial uses.

In a normal gasification process, a carbon raw material is fed into a heated container (gasifier) together with an appropriate amount of oxygen (a fixed amount or a small amount, or both) and, optionally, steam. Unlike incineration and combustion in which oxygen is oversupplied to produce CO ₂ , H ₂ O, SOx, and NOx, the gasification process produces a raw gas by mixing CO, H ₂ , H ₂ S, and NH ₃ . Useful main components obtained by gasification after purification are H ₂ and CO.
In addition to municipal waste and industrial waste, biomedical waste, sewage, sludge, coal, heavy oil, petroleum, coke, refinery heavy residue, refinery waste , Hydrocarbon-contaminated soil, biomass, agricultural waste, and hazardous waste such as tires. Depending on the nature of the raw materials, volatile substances are H ₂ O, H ₂ , N ₂ , O ₂ , CO ₂ , CO, CH ₄ , H ₂ S, NH ₃ , C ₂ H ₆ , acetylenes, olefins, It may contain unsaturated hydrocarbons such as aromatics, tars, hydrocarbon liquids (oils), and char (carbon black, ash).

When the raw material is heated, first, moisture is released. As the temperature of the dry ingredients increases, pyrolysis occurs. The raw material is converted into char by releasing tars, phenols and light volatile hydrocarbon gases by thermal decomposition.
Char is a solid residue made of organic and inorganic substances. The char remaining after pyrolysis has a higher carbon density than the dry raw material and may be a source of activated carbon. In a gasifier operating at a high temperature (above 1,200 ° C.) or a system having a high temperature region, inorganic minerals are fused or vitrified to form a material similar to molten glass called slag.
Since slag is fused and vitrified, it is usually judged harmless, and can be discarded as a harmless substance in landfills or sold as raw ore, roadbed or other construction materials. Dispose of waste by incineration because the fuel required for heating is wasteful, and it is also wasteful to dispose of useful syngas and substances that can be converted into solid materials as residual waste. Is less desirable than before.

  An object of the present invention is to provide a multi-zone carbon conversion device that converts a processing raw material into synthesis gas and slag. According to one aspect of the present invention, a multi-zone carbon conversion device is provided. It is provided with a carbon conversion zone and a slag zone in contact with it to melt the ash and keep the slag molten. The carbon conversion zone has one or more processing material supply ports, one or more synthesis gas discharge ports, and one heated air supply port, and the slag zone has a plasma heat source and a slag discharge port. Between the carbon conversion zone and the slag zone, there is an inter-zone region also called an inter zone. This functions as a barrier to limit or prevent mass transfer between the carbon conversion zone and the slag zone.

  In accordance with another aspect of the present invention, a multi-zone carbon conversion device for converting processing raw materials into synthesis gas and slag is provided. This device comprises a container with a carbon conversion zone and a slag zone in communication with each other, each zone being separated by an inter-zone region (interzone). The carbon conversion zone has a processing raw material supply port for obtaining a processing raw material from a supply source, a synthesis gas discharge port, and a heated air supply port. The interzone zone, also called the interzone, is a barrier that restricts mass transfer between the carbon conversion zone and the slag zone by partially or intermittently blocking the interzone zone (interzone), and optionally ash at the beginning of the start. It consists of a heat transfer element for melting. The slag zone has a plasma heat source and a slag outlet. In the carbon conversion zone, the processing raw material is converted into syngas and ash, and the ash is converted into molten slag in the inter-zone region (interzone), or in the slag zone by heating from the plasma heat source, or both.

This embodiment of the present invention will now be described by way of example only and with reference to the accompanying drawings as follows:
FIG. 1 is a block flow diagram showing the different zones of a multi-zone carbon converter, generally speaking, showing carbon conversion zones that are in contact to keep the ash molten and the slag molten. FIG. 2 shows a supply port of a multi-zone type carbon conversion device that constitutes a carbon conversion zone that communicates with the slag zone in order to melt the ash or keep the slag in a molten state by combining with a carbonaceous raw material gasifier It is a block flow diagram which shows. FIG. 3 is a general view of a so-called multi-zone carbon exchange apparatus. In particular, it shows the general characteristics of the carbon conversion zone, the inter-zone region (interzone) and the slag zone.

FIG. 4 is an overview diagram showing one specific example of a multi-zone type carbon exchange apparatus connected to a main gasification vessel. FIG. 5 illustrates a flange container design for a multi-zone carbon exchange device that facilitates the replacement of barriers and allows for the use of various fault configurations. FIG. 6 is a partial vertical cross-sectional view of one specific example of a multi-zone type carbon exchange device, in which obstacles (barriers) form a large number of ceramic spheres.

FIG. 7 is a longitudinal sectional view showing an inter-zone region (inter-zone) and a slag zone of one specific example of the multi-zone type carbon exchange apparatus showing in detail a dome-shaped helical gear-shaped barrier. FIG. 8 (A) is a partial longitudinal cross-sectional view of one specific example of a multi-zone type carbon exchange device, in which various ports for air treatment, ports for a starter burner, and gas from a hot gas generator are shown. Ports, slag outlets, barriers, etc. are shown in detail. FIG. 8B is a cross section cross-sectional view of the specific example described in 8A in level A-A. 8 (C) is a top view of the barrier and the wedge connected to the barrier. FIG. 9 is a cross-section cross-sectional view of one embodiment of a multi-zone carbon exchange device in which the barriers constitute a series of interconnected masses.

FIG. 10 is an illustration in which the barriers form one grid. FIG. 11 is a longitudinal cross-sectional view of an inter-zone region (interzone) and a slag zone of a multi-zone carbon exchange device in one specific example of the multi-zone carbon exchange device. FIG. 12 is a longitudinal sectional view of one specific example of a multi-zone type carbon exchange device, in which a lattice in which barriers move is formed. 12A and 12B show the details of the moving grid design.

FIG. 13A is a cross-sectional cross-sectional view detailing the ports in the slag in one embodiment of a multi-zone carbon exchange device, with oxygen or air supply (O), carbon emergency (C), and welding torch. Includes port (P) and gas burner port. FIG. 13B is a partial vertical cross-sectional view of one specific example of the multi-zone carbon exchange apparatus shown in FIG. 13A. FIG. 14 is an enlarged view of FIG. 13B. FIG. 15 is a partial vertical cross-sectional view of one specific example of a two-zone type carbon exchange apparatus showing in detail a plasma heat deflector and a slag thorn. FIG. 16 shows an improvement of the multi-zone type carbon exchange device, in which the slag zone further forms a weir to form a slag water mass to promote mixing of the slag.

FIG. 17 is a partial longitudinal cross-sectional view of one specific example of a multi-zone carbon exchange device, showing in detail one specific example of a slag cooling system including water injection and a drag chain. FIG. 18 is a perspective view of one specific example of the multi-zone type carbon exchange apparatus showing the processing raw material supply port and various ports in detail. FIG. 19 is another perspective view of one embodiment of the multi-zone carbon exchange apparatus showing in detail the processing raw material input, the syngas outlet, and the plasma torch depicted in FIG.

FIG. 20 is a longitudinal sectional view of the entire multi-zone type carbon exchange apparatus shown in FIGS. 18 and 19, and details the barrier between the carbon conversion zone and the slag zone. FIG. 21 depicts in detail the barrier between the carbon exchange zone and the slag zone of the multi-zone carbon exchange apparatus shown in FIGS. FIG. 22 is a cross-sectional cross-sectional view of the entire air chamber of the multi-zone carbon exchange apparatus shown in FIGS.

FIG. 23 shows a cross-section cross-sectional view of the entire multi-zone carbon exchange apparatus of FIGS. 18 and 23 at the torch level depicting in detail the independently installed air supply and plasma torch. FIG. 24 is a cross-sectional cross-sectional view of the entire multi-zone type carbon exchange apparatus in FIGS. 18 and 23 as seen at the burner level. FIG. 25 shows the multi-zone carbon exchange apparatus of FIGS. 18 and 23 from another angle.

FIG. 26 is a perspective view of one specific example of a multi-zone type carbon exchange apparatus showing in detail the various ports constituting the feed port of the processed raw material and the lattice-like barrier. FIG. 27 is a depiction of one embodiment of a multi-zone carbon exchange device showing that the barriers are connected together to form a series of chunks. FIG. 28 is a depiction of one embodiment of a multi-zone carbon exchange device showing that the barriers form a lattice that is primarily vertically.

FIG. 29 is a depiction of one embodiment of a multi-zone carbon exchange device showing that the barrier forms a geared dome. FIG. 30 is a depiction detailing a specific example to replace the multi-zone carbon exchange apparatus.

FIG. 31A depicts the air flow of one embodiment of the illustrated multi-zone carbon exchange device, respectively. FIG. 31B depicts the air flow of one embodiment of the illustrated multi-zone carbon exchange device, respectively. FIG. 32 is a depiction detailing a specific example to replace the multi-zone carbon exchange apparatus. FIG. 33 is a depiction detailing a specific example to replace the multi-zone carbon exchange apparatus.

Detailed description of the invention
DEFINITIONS Technical and scientific terms used below shall have the same meaning as commonly understood by the general engineer involved in the present invention.
The term “processing raw material” as used herein includes: They are char, low / ultra low volatility raw materials with non-volatile carbon and ash components, by-products from carbonaceous raw material gasification and pyrolysis processes, products obtained from incomplete combustion of carbonaceous raw materials, or gas Such as solids collected by a cleaning system with conditioning and heat source input from the plasma torch.

The term “syngas” as used herein is defined as a mixture of gases with various amounts of carbon monoxide and hydrogen generated by the gasification of carbon that keeps the fuel in a gaseous substance with thermal value. Syngas consists mainly of carbon monoxide, carbon dioxide, and hydrogen, and has an energy density less than half that of natural gas. Syngas is flammable and is often used as a fuel source or intermediate for producing other chemicals.
“Processing synthesis gas” is a synthesis gas that has been purified or re-invented using plasma hot gas purification and re-invention.

  The term “sensing element” as used below is defined as all elements of a system configured to sense the characteristics of a process, process device, process input, and process output. There, such characteristics may be expressed as characteristic values that can be used to monitor, control, and enforce one or more regional, regional, or global processes of the system. Sensing elements considered to be in the context of this system may include, but are not limited to: They include sensors, detectors, monitors, analyzers, etc. as well as process processes, fuel or material temperature, pressure, flow, synthesis state and other properties, and the substance at any point on the system. It may include any combination aimed at sensing the state and action, as well as the operational characteristics of any process device on the system. It will be appreciated by those of ordinary skill in the art that the above examples of sensing elements are each important on the system, but may not be important in recent invention disclosures. Also, the elements themselves recognized as sensing elements here should not be limited, nor should they be interpreted inappropriately in light of these examples.

  The “response element” used here is a pre-determined, calculated, or fixed or adjustable control parameter that responds to perceived characteristics to effectively operate the process device. Clarified to depict all elements of the configured system. There, one or more control parameters are specified to produce the desired process result. Response elements considered within the context of this system include, but are not limited to, static, preset, or dynamically changing drivers, or configured to convey power sources and actions It can be said that it refers to other elements. And it may be mechanical, aerodynamic, hydraulic, or a combination of each for a device based on one or more control parameters. Although one or more response elements may work together, possible process devices in the context of this system are not limited to the following, such as material or raw material input means, plasma heat sources, etc. Heat source, additional input means, various gas evacuators or gas circulation devices, various gas flow or pressure regulators, and any other regional, regional and global processes within the context of this system It can be said that other process devices that act to influence are included. It will be appreciated by those skilled in the art that the above examples of response elements are each important on the system, but may not be important in recent invention disclosures. In addition, the elements recognized as response elements here should not be limited, nor should they be construed inappropriately in light of these examples.

Overview of the System Referring to FIG. 1, there is provided a multi-zone carbon converter that converts process feedstock into synthesis gas and inert slag material. The multi-zone carbon conversion apparatus constitutes a container in which heat-resistant substances are arranged. And the container may include one or more supply ports for receiving the processed raw material, one or more outlets, one slag discharge port, an air supply port that facilitates converting the processed raw material into synthesis gas and ash, It then holds the heat necessary to melt the ash into slag and optionally steam, or a plasma heat source for processing additional products. Optionally, the processed raw material is pretreated (homogenized, ground, shredded or pulverized) before being fed to the converter. In particular, the multi-zone type carbon conversion device comprises a first zone and a carbon conversion zone that communicate with the first zone and the slag zone, and dissolves the remaining substantially carbon-free solid material in the dissolved slag, thereby bringing the slag into a dissolved state. With the purpose of keeping. The carbon conversion zone and the slag zone are divided into interzone regions or interzones that constitute barriers that limit or limit the movement of materials between the two zones, and some forms It may then provide an initial dissolution that dissolves the remaining virtually carbon-free solid material (eg, ash).

Current multi-zone carbon converters are optionally used in conjunction with a system that generates processing raw materials from carbon raw materials. For example, the multi-zone carbon conversion device (10) can obtain processing raw materials from the low-temperature gasification device (15) (see FIGS. 2 and 4). In such a situation, the multi-zone carbon converter is gasified in the sense that the third stage of the gasification process (eg, carbon conversion) is virtually complete in the multi-zone carbon converter. It may be considered an extension of the device.
In general, the gasification of a carbon feedstock can be subdivided into three stages, in particular, a drying stage, a volatilizing stage, and a char to ash (or carbon) conversion stage.

First stage: The first stage of the material dry gasification process is drying, which occurs mainly between 25 ° C and 400 ° C. Some volatilization and char to ash conversion may also occur at these low temperatures.
Second stage: The second stage of the volatile gasification process of the material is drying, which occurs mainly between 400 ° C and 700 ° C. As with some carbon conversion (char to syngas), a small amount of volatility (remaining) will also occur at this temperature.
Third stage: Char to ash conversion The third stage of the gasification process of carbon conversion occurs in the temperature range between 600 ° C and 1000 ° C. Small amounts (remaining) volatilization will occur at this temperature. After this stage, the main substances are virtually non-carbon solid residue (ash) and synthesis gas. To avoid ash crowding, the maximum temperature in this temperature range should not exceed about 950 ° C.
During gasification, it is necessary to maximize the conversion of the carbon feedstock to the desired gas material in order to increase the production of the desired syngas material. Therefore, the multi-zone carbon conversion system facilitates the recovery of synthesis gas and slag material, while providing a system that allows complete conversion of the remaining carbon in the process feed to synthesis gas. provide. The multi-zone carbon converter therefore also supplies additional hot air and optionally, for example, steam, or rich carbon gas, or to facilitate the conversion of carbon to the desired synthesis gas. Or, processing and supplying additives such as carbon.
Multi-zone carbon converters also provide plasma heat to facilitate complete conversion of residual inorganic material (eg, ash) to glassy solids or slag.

The multi-zone type carbon conversion apparatus is composed of a heat-resistant cover container, which is composed of the following. (B) Synthetic gas outlet, (b) Hot air inlet, (c) Slag outlet, (ii) One or more ports for plasma heat sources such as plasma torches, (e) Optional or Multiple processing inlets and ports. The multi-zone carbon converter also serves as a control subsystem for optionally monitoring operating parameters and adjusting the operating conditions within the converter to optimize the conversion reaction.
The sensing element and the response element are integrated in the conversion device, and the response element adjusts the operating status in the conversion device according to the data obtained from the sensing element.
The multi-zone carbon conversion device includes a first zone or carbonization conversion zone that communicates with the second zone or slag zone to dissolve residual solid material (eg, ash) and / or to maintain the slag in a dissolved state. Constitute. Between the carbon conversion zone and the slag zone, there is an inter-zone region also called an inter zone. This serves as a barrier to guide or limit mass transfer between the two zones. The inter-zone region and the inter-zone optionally provide an initial dissolution that dissolves the remaining virtually carbon-free solid material (eg, ash) into the molten slag, or promotes air diffusion and mixing.

FIG. 3 is a graphical depiction of one specific example of a multi-zone carbon exchange device (10). The multi-zone type carbon exchange device (10) is made by connecting a processing raw material supply port (20) to a carbon conversion zone (11) of a heat-resistant cover container (15). There, the hot air supply port (35) converts unarrived carbon of the processing raw material into synthesis gas. The remaining virtually carbon-free solid material (eg, ash) is converted to dissolved slag material, which occurs in the interzone region, or in the interzone and directly or indirectly (through the heat transfer element) Occurs in slag zones with the utility of Optionally, interzone zones and interzone barriers serve as heat transfer elements to convert the plasma heat source into residual solid material (eg, ash) and thereby affect initial dissolution. The inter-zone region and inter-zone may further constitute additional heat transfer elements to efficiently convert the plasma heat. The molten slag material is the product from the slag zone of the multi-zone carbon exchanger and passes to the optimal slag cooling subsystem for cooling. Syngas is the output from the converter and is optionally returned to the main gasification vessel where it is combined with the gas material from the main gasification process or further flowed to be processed or saved. It is accumulated in the tank.
A variety of materials are used as raw materials for processing as inputs to the multi-zone type carbon exchange apparatus. It can be obtained from by-products of carbonization raw material gasification, pyrolysis-treated products obtained from incomplete combustion of carbon fuel, or obtained by adjusting the gas or washing together with heat source materials from the plasma torch. It can be a solid.

Multi-zone carbon exchange equipment promotes the production of synthesis gas and slag by continuously promoting carbon conversion and dissolution of the remaining virtually carbon-free (eg, ash). This is accomplished by allowing carbon exchange to occur at a constant temperature before remaining carbon free (eg, ash) is exposed to higher temperatures. A multi-zone carbon exchange device minimizes or removes some carbon trapped in the melt.
In particular, the carbon conversion process consists of providing the processing material with the proper level of oxygen, and the temperature of the processing material is exposed to the specific environment of the carbon conversion zone by exposing the processing material to the specific environment of the carbon conversion zone. It consists of raising carbon to the level necessary to transform it into synthesis gas. Syngas produced in the conversion process exits the container through a gas outlet.

The produced synthesis gas may contain heavy metals and particulate contaminants. Thus, in one form, the multi-zone carbon exchange device further optionally constitutes a gas conditioning subsystem for cooling and regulating the residual gas required for downstream applications. Alternatively, the multi-zone carbon exchange device may be coupled to a subsequent gas conditioning or gas storage system.
The starting point of the processing raw material is not limited to this, but it may be a low-temperature / high-temperature gasifier, a pyrolyzer, and a hopper at a location for storing a distillate, or a baghouse filter, for example. Or a particulate separator in a gas conditioning system, such as a dust collector. The multi-zone type carbon exchange apparatus is directly or indirectly connected to the base point of the processing raw material. This raw material is conveyed continuously / intermittently from the raw material's origin through a moderately adjusted outlet and transport medium to the container's raw material inlet, at which time it is necessary for the system. It will be confirmed by a skilled worker according to the conditions and type of by-product to be removed. Optionally, the processing ingredients are pretreated before being charged into the container. Pretreatment includes, but is not limited to, homogenization, grinding, powdering, slicing, source fragmentation, or metal removal.

For example, molten slag is continuously produced from a multi-zone carbon exchanger at a temperature of about 1200 ° C. to about 1800 ° C. and then cooled to form a solid slag material.
Such slag material may be discarded in landfills or crushed into gravel for further general use. Alternatively, the molten slag can be injected into a mold to cast ingots, bricks, tiles, or similar construction materials. The resulting slag material will be utilized as a supplemental cement material for concrete, in the production of lightweight gravel and mineral wool, foam glass, and in the development of packaging materials.
Further, the multi-zone carbon exchange device also includes a subsystem that cools the molten slag to a solid state. The slag cooling subsystem is provided to adequately tolerate slag material cooled in a format that meets the requirements.

The multi-zone carbon exchange device also optionally has a control system to manage its carbon conversion and dissolution process. In particular, the multi-zone carbon exchange device has both a sensing element for the operating parameters of the system and a response element for adjusting its operating status in the system that manages the conversion process, where the response element is: Based on the data obtained from the sensing element, the operating conditions are adjusted in the system, thereby efficiently promoting complete carbon conversion and dissolution. Examples of adjustable operating parameters include the following: They are plasma heat rate (force) and position, process feed rate, air and / or steam, and / or rich carbon gas, and / or carbon-containing gas input, and / or carbon input.
Multizone Carbon Exchanger Referring again to FIG. 3, the multizone carbon exchanger (10) has a heat-resistant cover that has both a first end (processing raw material supply port end and a second end (slag discharge port end). The converter is composed of the following: a processing raw material supply port (20), a synthesis gas discharge port (25) and a slag discharge port (30); There is a plasma heat source (40), a hot air supply port (35), one or more additional supply port groups (not shown), and optionally a control system.
Further, in FIG. 4, a representative multi-zone carbon exchange device associated with the main gasification vessel is depicted schematically. In the multi-zone type carbon exchange device (10), the processing raw material supply port (20) is connected to the carbon conversion zone (11), in which the hot air supply port (35) is used to leave the processing raw material as synthesis gas or residual gas. Converted to a substantially carbon-free solid (eg ash). The synthesis gas material is discharged through the synthesis gas outlet (25). Residual solid material (e.g. ash) can be removed indirectly (e.g., through the use of thermal conversion elements) or through direct application of plasma heat, between zones, or inter-zone (12), and / or slag zones ( 13) is dissolved in slag. The molten slag material is the product in the slag zone and is sent to an optional cooling subsystem for cooling. The syngas product from that vessel is optionally sent back to the main gasification vessel, where it is mixed with gaseous material from the main gasification process, or it is sent to a subsequent process or storage system. .

Container Design Considerations The multi-zone carbon exchange vessel provides a sealed, insulated space for processing raw materials into syngas, and the syngas continues to cooling, purification, and other subsequent processes. And is designed to allow ash to be processed into slag. The container design encourages the formation of two zones and reflects the specific requirements of each of those zones. The design can optionally provide access to the interior of the multi-zone carbon exchange for inspection, maintenance, and repair. Referring to FIG. 5, the container is optionally a flanged container to facilitate replacement of individual zones, inter-zone regions, or individual zone parts.
The multi-zone type carbon exchange apparatus is composed of a carbon conversion zone, an inter-zone region or inter-zone, and a slag zone. The carbon conversion zone is used as follows: a) Supplying and adjusting processing raw materials, b) Supplying hot air, synthesizing inactive carbon in the processing raw materials with exothermic value and virtually no carbon residue C) convert to gas, c) supply optional processing additives such as steam or concentrated carbon gas, and 2) discharge the synthesis gas and solid residue. The interzone zone and interzone are designed to separate the carbon conversion zone and the slag zone, or to regulate the flow of material between the two zones, and optionally, the plasma heat is transformed into a solid residue. The solid residue can be prepared for initial dissolution in the slag. The slag zone is adjusted so that substantially carbon-free solid residue from carbon conversion forms molten slag (and optionally any residual carbon is converted to gas) or to maintain the dissolved slag in a molten state It is designed to discharge the molten slag and gaseous substances at appropriate locations to supply heat. Optionally, the slag zone can further configure or be connected to a slag cooling subsystem to facilitate solidification of the molten slag. Therefore, the container of the carbon conversion device having two zones is composed of a processing raw material supply port, a hot air supply port, a gas discharge port, a slag discharge port, a plasma heat source, and optionally one or a plurality of additional supply ports. A heat-resistant type, generally a vertically oriented container. In determining the size of an individual zone, the function of that individual zone is considered. In the carbon conversion zone, as much carbon as possible is converted to the gas phase. The slag zone functions to completely dissolve the ash. The carbon conversion zone is measured by the inflow and outflow of air at the point where the most amount of carbon is converted while remaining in a sub-stoichiometric environment at the highest operable temperature. The cross-section portion is based on the apparent speed required, so the operating state is not moving bed but is based on a fixed bed mode. The dimensions of the slag zone are calculated to maintain the ash at a high temperature level so that the ash is intimately melted with the heat supply from the plasma heat source, based on temperature balance.

Multi-zone carbon exchange equipment containers are designed to ensure that carbon conversion and ash processing are performed efficiently and completely, and the amount of energy used to complete these processing processes efficiently. There is a purpose to minimize. Therefore, when designing the container, factors such as efficient thermal conversion, sufficient heat temperature, residence time, dissolved slag flow, residual charge, mixture, etc., as well as its size and container Insulating. The containers are also designed to ensure that their processing is performed in a safe manner. Thus, multi-zone carbon exchange devices are designed to isolate the processing environment from the external environment. In general, the container is particularly adapted for the carbon exchange process at the top end near the base of the processing raw material, and particularly for the dissolution process at the base near the slag outlet.
Instead, the vessel is designed such that the carbon conversion zone is the core setting zone and the slag zone surrounds the carbon exchange zone. In such a form, the separation of the carbon exchange zone and the slag zone is achieved by raising the carbon conversion zone relative to the slag by using an inclined floor.
Optionally, the vessel is shaped to facilitate and facilitate the separation of the carbon exchange zone and the slag zone. Accordingly, in one form, the inter-zone region and the interzone form a constricted portion of the container (see FIG. 20).

The substance multi-zone type carbon exchange device is a heat-resistant container, and has an internal volume of a size that can accommodate an appropriate amount of substance during the required solid residence time.
The container is typically made of multiple layers of material in a reasonable condition. For example, the outer layer, or skin, is typically metal. Furthermore, it may be beneficial to add one or more thermal insulation layers between the internal heat-resistant layer and the external metal outer plate to reduce the temperature of the iron pipe. It can be said that the insulation board on the entire outer surface of the slag storage part is also provided to lower the temperature of the iron pipe. Optionally, a ceramic covering may be used as the insulator. When there is room for expansion of the refractory material without cracking, a compressible material such as a ceramic covering can be used in place of the metal skin. The insulating material is selected to provide a sufficiently high temperature to the skin to avoid acid gas liquefaction if it is an important issue. However, the temperature is up to a height that does not compromise the good condition of the outer skin.

  The refractory material protects the container from high heat and corrosive gases, minimizing unnecessary heat loss in the process. The refractory material can be an ordinary refractory material well known to engineers, and can be used in a non-pressurized reaction state at high temperatures (eg, temperatures of about 1100 ° C. to 1800 ° C.). Suitable for Factors to be considered when choosing a heat-resistant system include the following: a) wear, b) erosion and corrosion, c) suitable thermal protection / outer tube temperature limits, and b) heat resistance. Such as a suitable lifetime for the substance. Examples of suitable refractory materials are high temperature combustion ceramics, aluminum oxide, aluminum nitride, aluminosilicate, cubic boron nitride, zirconium phosphate, glass ceramics, and high aluminum pieces including silica, alumina, chromia, tiania, etc. ,and so on. In addition, to protect the container from erosion build-up, the container is optionally, partially, or entirely covered with a protective membrane. Such membranes are academically recognized and a skilled person can easily find the right membrane according to the needs of the system. Also included as an example is Sowereisen high temperature membrane No. 49.

In one form, the refractory material is a multi-layer design with a dense layer inside and can withstand high temperatures, wear, erosion and corrosion. The outer side of the high density material is a low density material having a low resistance but a high thermal insulation element. Optionally, the outside of this layer can be used because it is a very low density foam board material with a very high thermal insulation element and is not subject to erosive wear. Suitable materials for use in multi-layer refractory materials are known academically.
In one form, the multi-layer refractory material is an internally gathered chromia layer, ie, an intermediate alumina layer and an outer insboard layer.
Optionally, the refractory material in each individual zone and region may be applied in a limited manner depending on the environment of the particular part within the container. For example, a dense heat-resistant substance is used for the bottom part of the container because the actual temperature is high. In addition, slag zone refractory materials are applied to withstand higher temperatures and are designed to prevent slag from penetrating into refractory materials, thereby reducing refractory material corrosion. right.

The container wall can incorporate support for heat resistant walls and heat resistant fixatives. Appropriate heat resistant supports and fixatives are also known academically.
Due to harsh operating conditions, it is expected that this refractory material will require regular maintenance. Thus, in one form, the container is flanged to provide an detachable top and bottom, where the bottom of the container (with the reservoir attached) can be removed from the top of the container. In one form, the lower part can be dropped from the upper part to facilitate maintenance. This configuration is provided so that the lower part can be removed without obstructing any connection between the upper part of the container and the upstream / downstream part of the system.
Carbon conversion zone This carbon conversion zone is achieved by raising the temperature of the processing raw material to the level necessary for the processing raw material to convert the carbon in the processing raw material into synthesis gas, the conversion being processed This is done by exposing the raw material to the specific environment of the carbon conversion zone. The synthesis gas produced in this conversion process is discharged through the gas outlet. In one form, the synthesis gas is pushed back into the gasification vessel where it mixes with the various gases produced in the main gasification process.

Referring to FIG. 4, the carbon conversion zone (11) comprises one or more supply ports (20) for receiving processing raw materials and one or more synthesis gas discharge ports (25). Accordingly, communication is made through the inter-zone area or the inter-zone (12).
The carbon exchange zone (11) provides a hot air supply port to provide the temperature necessary to convert any remaining volatiles and carbon to synthesis gas. This container is also designed to ensure that the remnant is very efficiently exposed to hot air and has the purpose of minimizing the amount of suitable heat lost through the material gas.
The processing raw material supply port multi-zone type carbon exchange apparatus includes a processing raw material supply port coupled to a processing raw material injection port of the conversion container. The processing material inlet is applied such that the processing material is received through the carbon conversion zone of the vessel. The input to the processing material container may be passive (eg, by gravity, etc.) or may be active. As an option, the processing raw material supply port actively carries the processing raw material from its source to the inlet of the converter vessel. Appropriate and active transport mechanisms are also known academically, including double lock hoppers, screw conveyors, drag chains, etc., but other means are also known academically, such as holding down by air. .

It can be said that the processing ingredients placed in the container come from one or more sources. For example, but not limited to the following, ups such as low-temperature or high-temperature gasifiers, hoppers in places where residues from the gasification process are stored, or fly ash from baghouse filters and dust collectors Such as a stream gas preparation system.
If the process feed is supplied from multiple feed streams, or from multiple sources, a different stream will be sent to the container through each dedicated inlet. Alternatively, they may be mixed before being introduced into the container. In the latter form, one processing raw material inlet for supplying all of the processing raw material is supplied. Therefore, it can be said that this container has a common inlet or a plurality of inlets.
It can be said that the source of this processing raw material is supplied in direct communication with the container of the multi-zone type carbon exchange apparatus. That is, each processing raw material input is sent directly from its source to the container. Instead, the source is supplied in direct communication with the container. There, the residual input is conveyed from its source to the container through a system of means of transport.

In the case where the container of the multi-zone type carbon exchange apparatus is indirectly connected to the source of the processing raw material, the processing raw material supply port has one or more means for transporting the processing raw material from the source to the container. For example, the processing material includes a single screw conveyor or a series of screw conveyors, belts, pistons, plows, rotating arms, rotating chains, traveling greats, pusher rams, and the like.
The container of the multi-zone type carbon exchange device is optionally equipped with an air lock in cooperation with the processing raw material supply port. This optional airlock is installed to provide a barrier between the source of processing ingredients (and ambient air to prevent excess air inhalation) and the interior of the container.
The processing material supply port has an optional control system. It can control the feed rate of processing raw materials to achieve optimal carbon conversion and dissolution, and homogenization of residual materials.

The processing feed port is optionally included with or associated with a pretreatment module. The pretreatment includes a process for making the processing raw material identical or reducing, and includes, for example, a polishing operation, a pulverization operation, a homogenization operation, and the like. Appropriate polishers, grinders and homogenizers are known academically.
Carbon conversion zone heat system The carbon conversion process requires heat. Heat addition may occur directly by partial oxidation of the processing material (eg, a heat release reaction of carbon or volatile material present in the processing material with oxygen in the air material) or one or more known in the art. It happens indirectly by using the heat source.

The heat needed to convert unreachable carbon in the process feed is supplied (at least in part) through the use of burned air.
Hot air is supplied, for example, by air boxes, air heaters, heat exchangers, all known academically.
In one form, hot air is sent to the carbon exchange zone by a heat benefit and distribution system with a supply port located near the inter-zone region and the inter-zone. Appropriate air benefits and distribution systems are known in the art and for each stage following hot air can pass through a hole in the container wall or through an air nozzle or sprayer. Including air box.
Additional, complementary heating that may be needed is obtained from one or more academically known means, but is not limited to gas burners.

In one form, the additional heat source can be circulating hot sand.
In some forms, the additional heat source can be an electric heater or an electric heating element.
To facilitate the initial start-up of the multi-zone carbon exchange device, the vessel has an access port sized to accommodate various common burners, such as natural gas, oil / gas or propane burners, for preheating. .
Processing additive feed port Processing additives can optionally be added to the carbon exchange zone to facilitate efficient conversion of processing raw materials to synthesis gas. The steam inlet can be used to ensure that sufficient free oxygen and hydrogen are maximized to convert the decomposed elements of the process feedstock into synthesis gas or even a harmless mixture. The air supply port maximizes carbon conversion to fuel gas (minimizing free carbon) and maintains a chemical equilibrium process that maintains the optimum processing temperature while minimizing the heat cost of the supply port. Can be used to help. In addition, oxygen or ozone may be supplied to the carbon conversion zone through the processing additive feed port.

Optionally, other additives can be used to optimize the carbon conversion process, thereby improving emissions.
Optionally, rich coal gas can be used as a processing additive.
Thus, the carbon conversion zone can have one or more processing additive feeds. These include inlets for steam injection and / or air injection and / or rich gas. A steam inlet can be strategically installed to direct the steam to the hot zone and / or to the synthesis gas accumulation just before the steam is discharged from the converter. An air supply can be strategically installed in or around the container to ensure that the entire processing additive is present in the carbon conversion zone.
In one embodiment, the processing additive supply port is located in the inter-zone region or near the interzone.

In one embodiment, the processing additive feed provides a diffused low speed input of additive.
A number of examples where hot air can be used as an additional air / oxygen inlet for the vessel are optionally provided.
The inter-zone zone or inter-zone zone zone or inter-zone has the function of clearly and spatially separating the carbon conversion zone from the slag zone. And as an option, it allows the initial dissolution of the carbon-converted residual solid material (eg, ash) from efficiently converting the plasma heat into the residual solid material. The inter-zone region or inter-zone further includes a conduit or a connection between the two zones. Inter-zone zone or inter-zone limits or regulates the movement of materials between carbon conversion and inter-zone by occlusion of inter-zone zones or inter-zones in part or in places It has a barrier and prevents unconverted carbon from migrating to the melt, and can optionally constitute a thermal conversion element.

Referring to FIG. 6, in certain embodiments, the zones can optionally be contacted with a slag zone.
Barriers Barriers limit or regulate the movement of matter between the carbon conversion and slag zones by occlusion of interzone zones, or interzones, in part or in places. To do. There may also optionally be provision for thermal conversion.
The barrier is attached within the inter-zone region or the inter-zone, and has various shapes and designs. It may be, but is not limited to, a dome shape, a pyramid shape, a lattice, a moving clay, a brick clay, a myriad of ceramic spheres, a large number of tubes, and a cogwheel type. The barrier and any necessary mounting elements work efficiently even under the harsh conditions of a multi-zone carbon exchange device, especially at high temperatures. Thus, the barrier is constructed of a material designed to withstand high temperatures. Optionally, the barrier may be a refractory system or a solid refractory material.

Referring to FIGS. 6-10, they illustrate various alternative, unlimited barriers in detail.
In one embodiment shown in FIG. 6, the barrier consists of a myriad of ceramic spheres.
In one embodiment shown in FIG. 7, the barrier comprises a heat-resistant dome of the cogwheel type.

In one embodiment shown in FIG. 8, the barrier is one solid refractory dome (145) fitted with a wedge-shaped inset brick (150) in the interzone region. The solid refractory dome is measured such that there is some gap (155) between the outer edge of the dome and its inner wall. Optionally, the refractory dome may further consist of a myriad of holes (160).
In the illustrated embodiment, optionally an infinite number of aluminum / ceramic spheres between 20 and 100 mm in diameter are placed on top of the heat-resistant dome to form one bed, It provides the diffusion of hot air and facilitates the conversion of plasma heat into the ash in order to initially dissolve the ash into the slag. In this embodiment, as the ash melts, the ash passes through the interzone region to pass through the gap (160) between the outer edge (145) of the dome and the inner wall of the container, and the slag zone Move to.
Referring to FIG. 9, the barrier consists of one solid refractory brick grid. The solid refractory brick grid (245) has gaps (255) between the individual bricks to allow communication between the carbon conversion zone and the slag zone through the interzone region.

Referring to FIG. 10, the barrier is made from a refractory tube (345) mounted in a single telescoping ring (350).
Referring to FIG. 12, the barrier consists of a movable grid.
In the thermal conversion element and diffusion element option, the inter-zone region may further comprise a thermal conversion and diffusion element that facilitates the conversion of plasma heat. The thermal conversion element is a ceramic sphere, an agate, or a brick, as is known in the academic field.

In one embodiment, the thermal conversion element is made up of a myriad of aluminum or ceramic spheres (165), with a myriad of aluminum / ceramic spheres between 20 and 100 mm in diameter forming one bed. By supplying hot air diffusion and converting the plasma heat into ash, it promotes the ash to be dissolved in the slag by the initial dissolution.
Optionally, the barrier may consist of the thermal conversion element.
As an optional heating element option, the interzone area and the interzone are accompanied by a heat source. Suitable sources of heat include air sources, electric heaters, or plasma heat sources including electric heating elements, burners, plasma torches and the like.

The optional plasma torch can be attached within the interzone region and / or at the carbon conversion zone / interzone region interface and / or at the interzone zone / slag zone interface.
Optionally, the carbon remaining in the ash is converted to synthesis gas by applying interzone or interzone plasma heat.
Thus, the container wall in the interzone region can include an access port sized to accommodate various heat sources.

The slag zone melting process is accomplished by raising the temperature to a level at which the remaining solid material (ash) that is substantially free of carbon melts, occurring in the interzone region and / or slag zone. The heat required for the melting process is supplied from one or more plasma heat sources. This heat may be applied directly but may also be applied via a heat transfer element. Plasma heat also plays a role in completely converting even a small amount of carbon remaining in the residue after carbon conversion by heated air input. The additional or supplemental heat is supplied as needed by one or more heating methods such as (but not limited to) induction heating and joule heating that are well known in the art.
The slag zone is supplied by a plasma heat source. The plasma heat source meets the temperature required to heat the ash to the level required to melt and homogenize the remaining solids (directly or indirectly) and is sufficient from the multi-zone carbon converter. Supply molten slag to a temperature sufficient to flow out. If necessary, the carbon remaining in the ash is converted to synthesis gas. The slag zone is also designed to ensure a very efficient heat transfer between the plasma gas and the residue or slag while minimizing the amount of significant heat lost. Therefore, in addition to the type of plasma heat source used, the position and direction of the plasma heating method are additional factors to be considered in designing the slag zone.

The slag zone is also designed so that the residence time of the residue is sufficient so that the temperature of the residue is raised to a temperature sufficient to completely dissolve and homogenize the remaining inorganic material.
Referring to FIGS. 13 to 16, if necessary, the slag zone is provided with a reservoir that accumulates residues heated by a plasma heat source. This reservoir also allows mixing in the adjustment process of solids and molten material. Having sufficient residence time and proper mixing ensures that the conditioning process is fully performed and that the resulting slag has the desired composition.
The slag zone has a sloping or sloping floor toward the slag outlet so that molten slag can escape easily.

The slag zone is designed to constantly produce molten slag material. By constantly removing slag, the adjustment process is carried out continuously, and the residues to be adjusted therein are also continuously input without interruption and processed by plasma heat, as normally required for periodic slag removal. Is done.
In one embodiment, continuous slag discharge is achieved by using a reservoir partitioned on one side by a weir (33). This weir allows the slag pool to accumulate until it reaches a certain level, at which point the molten slag can pass over the weir and out of the reservoir.
The place where the processing raw material is adjusted contains a large amount of metal, and the slag zone consists of reservoirs partitioned by weirs. The metal accumulates in the tank from its high melting temperature and density until it is generally removed. Accordingly, in one multi-zone converter embodiment, the reservoir is optionally provided with a metal tap port plugged with a soft heat-resistant paste, from which oxygen lance heat can be used for periodic maintenance. The hole is opened and closed. Once the tap port is opened and the room temperature has risen to a level sufficient to melt the accumulated metal, the molten metal is removed from the bottom of the reservoir. The outlet is re-sealed by filling the hole with a refractory material or other suitable material.

The slag zone walls and floors are exposed to very rigorous operational requirements, if necessary, because of the high temperatures required to condition the ash and, in particular, dissolve any remaining metal. It is covered with a sex substance. The selection of a suitable material for the slag zone design is made under several criteria. For example, the operating temperature reached during a typical residue adjustment process, thermal shock resistance, molten slag and / or resistance to wear and erosion / corrosion due to hot gases produced during the melting process. The porosity of the material is also taken into account when selecting the material for the slag zone.
The slug zone may also include one or more ports as needed to accommodate additional components or equipment needed. In one embodiment, the port is a viewport that includes a closed circuit television, if necessary, to allow the operator to fully see the ash treatment status, including monitoring the slag outlet for obstruction formation. There is a case. Reservoir rooms may include service ports that can be accessed and accessed for maintenance and repair. Such ports are well known in the art and can have seal holes of various sizes.

Plasma heat
The slag zone uses one or more plasma heat sources to convert the ash material produced by the carbon conversion process. The plasma heat source may be movable, fixed, or a combination thereof.
The plasma heat source may consist of various commercially available plasma torches that provide a suitable hot gas over time for application. Such plasma torches are generally prepared in sizes ranging from about 100 kW to 6 MW or more. The plasma torch can use a suitable working gas, either single or combined. Examples of suitable working gases include (but are not limited to) air, argon, helium, neon, hydrogen, methane, ammonia, carbon monoxide, oxygen, carbon dioxide. In one embodiment of the present invention, the plasma heating method operates continuously as long as it produces a temperature from about 900 degrees to about 1800 degrees so that the residue is converted to an inert slag product.

In this regard, many alternative plasma technologies are suitable for use in the slag zone. For example, when using appropriately selected electrode materials, it is recognized that transitional and non-transitional arc torches (both AC and DC) are used. It is also recognized that inductively coupled plasma torches (ICP) may also be used. Those skilled in the art should not have difficulty selecting an appropriate plasma heat source.
By using a transfer arc torch instead of a non-transfer arc torch, the efficiency of the residue adjustment process can be improved. This is because, in the latter case, the arc passes directly through the melt, which not only allows higher heat transfer efficiency between the hot plasma gas and the material being melted, but also increases the efficiency of electricity-to-heat conversion. It is for having. When a transition arc torch is used, the slag zone shell is connected to a power source, so it is necessary to ensure that the slag zone is electrically isolated.
In one embodiment, the plasma heat source is a DC non-transfer arc torch.
In one embodiment, the plasma heat source is a graphite torch.

In one embodiment of the multi-zone carbon conversion device, one or more plasma heat sources are arranged to optimize the conversion of residual material to inert slag. The location of the plasma heat source is selected according to the design of the residue conditioning chamber. For example, if a single plasma heat source is used, the plasma heat source is attached to the top of the chamber and is accumulated at the bottom of the chamber so that enough heat is applied to melt the residual material and the slag is forced to flow out. Arranged against the slag pool. In one embodiment, the plasma heat source is a plasma torch mounted vertically at the top of the chamber.
All plasma heat sources can be controlled in terms of power and position (if a moving heat source is used) as needed. In one embodiment, the plasma thermal efficiency varies to accommodate various residue input rates. Plasma thermal efficiency also varies to accommodate various residue melting temperature characteristics.

The plasma heat source operates continuously and discontinuously at the operator's discretion to accommodate various residue input rates and melting temperature characteristics.
If necessary, the slag zone may be equipped with a deflector (61) to divert or direct the plasma heat (see FIGS. 15 and 16).
Process additives such as process additive vapor, air, carbon, and / or carbon dioxide, and / or oxygen rich gas, and / or bag ash are added to the slag zone as needed. Thus, the slag zone is equipped with various input devices and / or the chamber with the slag zone further includes ports for these input devices.

The slag production slag zone includes a slag output device. The slag output device includes a discharge port through which molten slag in the room is discharged. The outlet is usually at or near the bottom of the chamber in order to encourage gravity flow out of the molten slag pool. The slag output device also has a subsystem that cools the slag as needed to encourage the molten slag to cool and solidify. Such cooling subsystems include, for example, water pools and sprays.
Molten slag is continuously extracted throughout the entire period of conditioning. The molten slag is cooled and collected in various ways apparent to those skilled in the art to form a thick, non-leachable solid slag.
As the ash is conditioned by the plasma heat, the resulting molten slag accumulates in the reservoir as needed. The resulting molten slag is continuously extracted. That is, as the amount of molten slag in the reservoir increases, the adjustment chamber is removed from the discharge port over the weir.

The continuous extraction embodiment is particularly suitable for systems designed to operate continuously.
In one embodiment, the slag output method also includes a slag cooling subsystem that cools the molten slag and provides a solid slag product. In one embodiment, molten slag is poured into a quench water bath (78). The water tub is an efficient system that cools the slag and crushes it into granules suitable for commercial applications such as concrete manufacturing and road construction. The water tub may also provide a blockade to the surrounding environment that extends from the bottom of the slag chamber to the lower water tub, which is a barrier that prevents external gases from entering the residue conditioning chamber. The solid slag product is removed from the water bath by a conveyor system. The slag cooling subsystem may also include a water spray.

In one embodiment of the slag cooling subsystem, the molten slag is dropped into a thick wall steel receiving container for cooling. In one embodiment, the molten slag is received in an environmentally sealed silica sand bed or mold that provides solid slag suitable for small scale processing or specific parameter inspection. Small molds are controlled and cooled in a preheated oven.
In one embodiment of the slag cooling subsystem, the molten slag is converted into a commercial product such as glass wool.
In one embodiment of a controlled multi-zone carbon converter, a control system is installed to control one or more processes incorporated into (or by) the converter. In general, the control system monitors the various processes so that the process feed is efficiently and completely converted into a syngas product and the solid residue (ie ash) is efficiently melted into the slag. Adjust.

The control system consists of one or more sensors for immediate monitoring of system operating parameters. The system also has one or more response elements to adjust the operating conditions in the system and optimize the conversion reaction. In the conversion reaction, the detection element and the response element are integrated in the system, and the response element adjusts the operating conditions in the system according to the data obtained from the detection element.
Control elements Detection elements that are considered in the current situation include methods for monitoring operating parameters such as temperature, pressure, gas flow, etc., in various parts of the system and methods for analyzing the chemical composition of syngas products (however, Not limited to).
The data obtained from the sensing elements is used to determine whether conditions or operating parameters in the multi-zone carbon converter need to be adjusted to optimize process efficiency and syngas product composition. By continuously adjusting certain operating conditions such as reaction materials (e.g., rate of processing feed addition, heated air and / or steam input) and the pressure of various components in the system, the synthesis gas is It has become possible to carry out this process under conditions of steady and efficient production.

The control system may be designed and configured for the purpose of maximizing the efficiency of the conversion process and reducing the impact on the environment. The control system may also be designed so that the multi-zone carbon converter operates under continuous operating conditions.
The following operating parameters are monitored by the sensing element intermittently or continuously. And the data obtained is whether the system is operating within the optimal set point, whether it should be powered further by the torch, air or steam should be injected into the system, or the raw material input rate can be adjusted Used to determine whether or not

Temperature In one embodiment, the control system comprises means for monitoring the temperature of sites at various locations of the multi-zone carbon conversion device, such as within a carbon conversion zone, an inter-zone region, or a slag zone, as required. Yes. Thermoelectric thermometers and optical thermometers installed at various places in the system as a means for temperature monitoring.
A means for monitoring the temperature of the hot synthesis gas product may also be installed at the synthesis gas outlet of the carbon conversion zone.
System pressure In one embodiment, the control system comprises means for monitoring the pressure at various points of the multi-zone carbon converter. These pressure monitoring means include pressure sensors such as pressure transducers, pressure transmitters, or pressure plugs, and are located anywhere in the system, for example, the vertical wall of the chamber.

Gas Flow In one embodiment, the control system comprises means for monitoring the synthesis gas flow. Variations in gas flow are the result of non-homogeneous conditions (eg, torch malfunction or material supply interruption). Thus, if gas flow fluctuations continue, the system may shut down until the problem is resolved.
Gas Composition In one embodiment, the control system comprises means for monitoring the composition of the syngas product. The gas produced during the conversion process is sampled and analyzed in a manner well known to those skilled in the art.

In one embodiment, the synthesis gas composition is monitored by a gas monitor. This is used, for example, to determine the chemical composition of synthesis gas, such as hydrogen, carbon monoxide, carbon dioxide. In one embodiment, the chemical composition of the syngas product is monitored through gas chromatography (GC) analysis. Sampling points for these analyzes are located throughout the system. In one embodiment, the gas composition is monitored using a Fourier Transform Infrared (FTIR) analyzer that measures the infrared spectrum of the gas.
Although hot gas analysis methods exist, those skilled in the art will understand the need to cool the gas prior to composition analysis, depending on the type of system used for gas analysis.

Response elements Expected response elements in the current situation include various (but not limited to) control elements that are operatively coupled to the process-related device, and the device may have specific control parameters associated with it. By adjusting, it is set to affect a specific process. For example, process equipment that can be operated in the current situation via one or more response elements includes processing raw material, air and / or steam addition rates, and power to the torch, torch position, etc. This includes, but is not limited to, adjusting various operating parameters such as conditions.
Plasma Heat Source Current carbon converters utilize the controllability of plasma heat to ensure that ash is completely melted into slag and vitrified reliably.
In one embodiment, the control system comprises means for adjusting the output of the plasma heat source and, if necessary, the position. For example, if the temperature of the melt is too low, the control system may command to increase the power rating of the plasma heat source, and conversely if the temperature of the chamber is too high, the control system will command to reduce the power rating of the plasma heat source. In some cases.

In one embodiment, the torch power is maintained at a level proportional to the residue addition rate. That is, when the residue supply rate increases, the torch output is also raised as a result. Torch power is also adjusted in response to changes in residue properties and composition with respect to melting properties such as temperature, specific heat capacity, heat of fusion.
In one embodiment, the position of the plasma heat source is adjustable so that the molten pool is completely covered and areas of incomplete reactants are removed.
Process Raw Material Addition Rate In one embodiment of the invention, the control system comprises means for adjusting the feed rate of the process raw material to the carbon conversion zone. The processing material may be added in a continuous manner or in a non-continuous manner, for example, by using a rotating screw or an Auger mechanism.
If the raw material input method consists of a series of push-in rams, in each case the control system may employ other progress control methods, such as limit switches or computer controlled variable speed motor drives, as required. The length, speed, and / or frequency of the ram stroke is controlled so that the amount of material delivered to each chamber is controlled with each stroke. If the input method consists of one or more screw conveyors, the material addition rate to the carbon conversion zone is controlled by adjusting the conveyor speed via a drive motor variable frequency drive.
The input rate is adjusted as necessary so that an allowable range can be controlled with respect to the conversion stage of the processing raw material. As a result, incompletely converted material is prevented from being carried from the carbon conversion zone.

In one embodiment of the invention, the control system controls the input rate and / or input of air or other process additives including carbon and steam into the carbon conversion zone and / or slag zone. Means to adjust are provided.
The input of heated air may be made as necessary to maintain an optimum processing raw material conversion temperature.
In one embodiment, the control system includes process control means for adjusting process additives based on data obtained by monitoring and analyzing the composition of the synthesis gas. By continuously obtaining gas composition data, it is possible to immediately adjust additive materials such as air and steam. The types and amounts of process additives are selected with great care to optimize the chemical composition of the syngas while complying with regulatory emission limits and minimizing operating costs.

Example
Example 1
Referring to FIGS. 8, 11, 18 to 25, the multi-zone carbon conversion device (110) is divided into an upper carbon conversion zone (111) and a lower slag melting zone (113) by an inter-zone region (112). It is separated. The carbon conversion zone (111) is maintained at a temperature from about 950 degrees to about 1100 degrees, and the slag melting zone is maintained from about 1350 degrees to about 1600 degrees.
Referring to FIGS. 8, 11, 18 to 25, in the illustrated embodiment, the multi-zone carbon converter (110) is comprised of a vertical chamber (115) lined with a heat resistant lining to supply processing raw material. It has a zone-by-zone heating system (ie, a system capable of establishing two temperature zones) consisting of a mouth (120), a gas outlet (125), a slag outlet (130), an air box (135) and a plasma torch (140). . If necessary, a pulverizer (not shown) can be attached to the processing raw material supply port as necessary in order to homogenize the size of the input material.

The chamber (115) is a heat-resistant lining steel weldment, the shape is substantially cylindrical with a roof, and the ratio of length to diameter at the widest point is about 3.6: 1. The chamber diameter is narrowed in the inter-zone region at the base of the throat and becomes thinner toward the slag outlet. In order to facilitate the exchange of various components, including components in the inter-zone region, the chamber is constructed by parts.
The refractory material consists of three layers. The inner layer is resistant to high temperatures, so the chromia-alumina castable (non-uniform refractory material), the intermediate layer, and the outer layer are plycast (Plicast) heat-insulating amorphous heat-resistant material It is an insulation board. In the lower part of the chamber container, the heat-resistant part is thicker due to a higher operating temperature, and 190 mm Shamrock 493, 115 mm Plicast LWI-28, 76 mm Insboard 2300HD, and 25 mm Durablanket are applied. The upper part of the heat-resistant portion is composed of 190 mm Plicast Hymor 2800, 114 mm IFB, and 100 mm Legrit Super Lite CD.

Referring to FIG. 22, heated air is introduced into the zone via an air box (135) near the downstream end of the carbon conversion zone. The supply of air to the air box is controllable so that the conversion process can be adjusted. The air flow rate is controlled by the supply / air ratio and operating temperature change. If desired, steam may be injected into the carbon conversion zone via the steam injection port (136).
Referring to FIG. 21, the carbon conversion zone (111) tapers into a narrower inter-zone region (112). The inter-zone region includes physical obstacles (145) to direct material flow from the carbon conversion zone to the slag zone. Referring to FIGS. 8 and 11, the physical obstacle consists of a solid precast refractory dome (145) installed in the interzone region using four wedge refractory bricks (150). The heat-resistant dome is sized so that a groove (155) or space is formed between the inner wall of the multi-zone type carbon conversion device and the dome, and mass transfer between the zones can be performed there. The groove is just sized to allow molten slag to pass through. If desired, the heat-resistant dome can have a plurality of holes (151).
A plurality of alumina or ceramic balls (165) of 20 to 100 mm in diameter are placed on top of the refractory dome to form a bed, resulting in the diffusion of heated air, first in the inter-zone region, Because the ash is melted into the slag, plasma heat transfer to the ash is facilitated. In this embodiment, as the ash melts, it passes through the groove (155) between the outer edge of the dome and the inner wall of the chamber and into the slag zone through the interzone region.

Slag zone (113) is located downstream of the inter-zone region. The slag zone (113) is a heat resistant lined cylinder with a single conical slag outlet (130).
The slag zone is comprised of various ports including a plasma torch port, a burner port for the burner (139) that preheats the chamber, and a port for process additives such as heated air, carbon and / or bag ash. Referring to FIG. 23, the slag melting zone comprises a plasma torch (140) and an air nozzle (141) with tangentially installed air conveyor gas and a heated air injection nozzle. The heated air, carbon, and / or bag ash and the plasma torch form a high temperature gas generator (HGG) to obtain a high temperature gas (1600 ° C. or higher) that promotes ash melting. The plasma torch is rated as 300 kW, water-cooled, copper electrode, NTAT, DC plasma. If necessary, carbon and / or bag ash may be injected using a carbon supply port or through an air nozzle. Referring to FIG. 24, the chamber further includes a port corresponding to a burner (139) that facilitates starting.
Referring to FIG. 25, upon exiting the slag zone, the molten slag passes through a water spray (113) where it solidifies into pieces. Slag particles are removed using the brake chain assembly (114).

The plasma torch (140) is installed on a slide mechanism that can move the torch (140) into and out of the slag melting zone. If necessary, the torch is approached for higher heat intensity. The torch (140) is sealed in the chamber by a sealed gland. The gland is sealed with respect to the gate valve. Similarly, the valve is installed and sealed in the container. To remove the torch (140), it is pulled out of the chamber (115) by a slide mechanism. For safety, the initial operation of the slide disables the high voltage torch power supply. When the torch (140) is pulled through the valve and the coolant circulation stops, the gate valve automatically closes. The hose and cable are disconnected from the torch (140), the gland is released from the gate valve, and the torch (140) is lifted by a lifting machine.
The torch (140) is replaced using the reverse of the above procedure. The sliding mechanism is adjusted so that the insertion depth of the torch (140) can be changed.
The gate valve is mechanically operated so that operation is automated. A pneumatic actuator is used to automatically retract the torch in the event of a cooling system failure. The compressed air for operating the actuator is supplied from a dedicated air tank so that the output is always available even in the event of a power failure. The same air tank also provides gate valve air. The electrical interlock cover is used as an additional safety feature by preventing access to the high voltage torch connection.
Thermoelectric thermometers, along with carbon converters, can be used in various ways to maintain the temperature in the zone at a pre-determined temperature and to increase power and air injection into the plasma torch if it falls below this temperature. It is arranged in a place.

Example 2
Since the carbon conversion zone and slag zone are substantially the same as described in Example 1, the general structure and design of the multi-zone carbon conversion device is as described above. Referring to FIGS. 10 and 26, in the illustrated embodiment, the multi-zone carbon converter (310) is comprised of a heat resistant lining, vertical chamber (315), and a process feed inlet (not shown). , A syngas outlet (325), a slag outlet (330), and a zoned heating system (ie, a system capable of establishing two temperature zones) consisting of an air inlet (not shown) and a plasma torch (340). Have.
Referring to FIGS. 10 and 26, the interzone region contains physical obstacles to regulate the flow of material from the carbon conversion zone to the slag zone. In the instant embodiment, the physical obstacle consists of a series of generally parallel heat resistant lining tubes (345) mounted in a mounting ring (350). The tubes are mounted so that there is a groove (355) between adjacent tubes. If necessary, a plurality of alumina or ceramic balls of 20 to 100 mm in diameter are placed on top of the refractory dome to form a bed and provide diffusion, first in the interzone region, the ash As the slag is melted into the slag, plasma heat transfer to the ash is promoted.
Heated air is supplied to the carbon conversion zone through perforations in the upper surface of a generally parallel heat resistant lining tube (345).

Example 3
Since the carbon conversion zone and the slag zone are substantially the same as described in Example 1, the general structure and design of the multi-zone carbon conversion device is as described above. Referring to FIG. 27, in the illustrated embodiment, the multi-zone carbon converter (210) is comprised of a heat resistant lining, vertical chamber (315), a process feed inlet (not shown), a synthesis Has a gas outlet (not shown), a slag outlet (230), and a zoned heating system (ie a system capable of establishing two temperature zones) consisting of an air inlet (not shown) and a plasma torch (240) .
Referring to FIG. 27, the inter-zone region includes physical obstacles to regulate material flow from the carbon conversion zone to the slag zone. In the instant embodiment, the physical failure consists of a series of interconnected refractory bricks (245). The brick is installed on the mounting element (250) so that there is a groove (255) between adjacent bricks.
Example 4
Referring to FIG. 28, in the illustrated embodiment, the multi-zone carbon conversion device (partially indicated) is comprised of a heat resistant lining, vertical chamber (415), and a raw material feed port (not shown). ), Synthesis gas outlet (not shown), slag outlet (430), and air inlet (435), plasma torch (440), and zoned heating system including hot water outlet (446) if necessary (Ie, a system capable of establishing two temperature zones).

Referring to FIG. 28, the carbon conversion zone is located in the center, and the slag zone is installed toward the periphery of the chamber. The chamber floor is inclined so that the carbon conversion zone is upstream of the slag zone. This encourages the material to move in one direction between these zones. The two zones are separated by an inter-zone region. The inter-zone region contains physical obstacles to regulate the flow of material from the carbon conversion zone to the slag zone. In the instant embodiment, the physical obstacle consists of a series of generally vertical, generally parallel, heat resistant lined perforated pipes (445). Heated air is introduced into the carbon conversion zone through the drilling of pipes into the center of the pile of processing raw materials. Therefore, the carbon in the processing raw material is heated and converted. As the air is sent from the bottom, it is heated slightly while cooling the pipe. Air is injected outside the pipe row through the air inlet (441) in the slag zone and serves to keep the outer surface of the pipe at a high temperature so that the slag does not freeze.
The slanted bottom of the slag zone helps flush out the residue on the side where the plasma torch is installed so that the residue melts into the molten slag. As the slag drains, it passes through the water spray and falls to the lower hopper.
Example 5
Since the carbon conversion zone and the slag zone are substantially the same as described in Example 1, the general structure and design of the multi-zone carbon conversion device is as described above. Referring to FIG. 29 showing a part of the carbon conversion zone, the inter-zone region, and the slag zone, the multi-zone carbon conversion device (510) is composed of a vertical chamber (515) lined with a heat resistant lining and processed. A zone-specific heating system (i.e., a two-phase heating system (i.e., two) System that can establish two temperature zones.
Referring to FIG. 29, the inter-zone region includes physical obstacles to regulate material flow from the carbon conversion zone to the slag zone. In the instant embodiment, the physical obstacle consists of a geared dome (545).

Example 6
Since the carbon conversion zone and the slag zone are substantially the same as described in Example 1 except for the design of the slag zone, the structure and design of the multi-zone carbon conversion device is as described above. It is. Referring to FIG. 30 (shown carbon conversion zone, inter-zone region, part of slag zone), the slag zone chamber comprises a plasma torch (640), carbon and / or bag ash feed (642), and heating. A branch or hot gas generator (622) with an air inlet (641) is included.
Example 7
Referring to FIG. 6, since the carbon conversion zone and slag zone are substantially the same as described in Example 1, the general structure and design of the multi-zone carbon conversion device is described above. That's right. Referring to FIG. 6 which shows a part of the carbon conversion zone, the inter-zone region, and the slag zone, the multi-zone carbon conversion device (610) is composed of a vertical chamber (615) lined with a heat resistant lining and processed. A zone-specific heating system (i.e., a two-phase heating system (i.e., two). System that can establish two temperature zones.
Referring to FIG. 6, the inter-zone region (continuous with the slag zone) contains physical obstacles to regulate the flow of material from the carbon conversion zone to the slag zone. In the instant embodiment, the physical obstacle consists of a plurality of ceramic balls (645).

Example 8
Referring to FIG. 32, the carbon conversion zone and the inter-zone region are substantially the same as described in Example 1, so the general structure and design of the multi-zone carbon conversion device is described above. It is as it is done. The floor of the slag zone consists of a rotating and tilting heat-resistant table. The rotation of the table top facilitates the discharge of molten slag. If necessary, the table may include a plurality of ceramic balls to facilitate plasma heat transfer. The slag zone floor may be raised from the treatment zone.
Referring to FIG. 32 showing a part of the carbon conversion zone, the inter-zone region, and the slag zone, the multi-zone type carbon conversion device (810) is composed of a heat resistant lining, a vertical chamber (815), and processed. By zone, consisting of raw material supply port (not shown), synthesis gas discharge port (not shown), slag discharge port (830), air inlet (not shown), plasma torch (840), and barrier (845) It has a heating system (ie a system that can establish two temperature zones).
The heat resistant lining table top is installed on a drive shaft (846) operatively connected to an external motor (847). The slag floor assembly is easily removable from the interzone area and the carbon conversion zone and is installed on a lifting table on rails for easy cleaning. A plurality of ceramic balls (848) facilitate plasma heat transfer.
If necessary, the molten slag is cooled by water spray as it exits the slag outlet (830), and the solidified slag falls onto the brake chain for removal.

Example 9
FIG. 33 shows a part of the carbon conversion zone, the inter-zone region, and the slag zone. The multi-zone type carbon conversion device (910) is composed of a vertical chamber (915) lined with a heat resistant lining, and is processed raw material. Supply port (not shown), synthesis gas outlet (not shown), slag outlet (930), air inlet (not shown) and plasma torch (940), propane or natural gas burner (937), and barrier (945), a zoned heating system (ie, a system capable of establishing two temperature zones).
The barrier consists of a rotating heat-resistant cone (921) installed on the drive base with a drive shaft (933) connected to an external motor (942). The lower part of the rotating refractory includes a well (978) in which slag accumulates prior to discharge from the chamber. The barrier / slag floor assembly is easily removable from the interzone area and the carbon conversion zone and is installed on a lifting table on the rails for easy cleaning.
If necessary, the molten slag is cooled by water spray as it exits the slag outlet (930), and the solidified slag falls onto the brake chain for removal.

Example 10
Referring to FIG. 12, in the illustrated embodiment, the multi-zone carbon converter (1010) is comprised of a heat resistant lining, vertical chamber (1015), a processing material supply port (1020), a plasma gas. Syngas outlet (1025) connected to the purification chamber (1066), slag outlet (1030), agitator (1031) with externally installed motor assembly (1032), air inlet (1041) and plasma torch (1040) with a zoned heating system (ie a system capable of establishing two temperature zones).
The inter-zone region contains physical obstacles to regulate the flow of material from the carbon conversion zone to the slag zone. In the instant embodiment, the physical obstacle consists of a rotating grate (1045) placed in the interzone area. The residual solid material passes through the inter-zone region and melts in the slag zone. 12A and B show a typical grate design.

Claims (12)

A chamber consisting of a carbon conversion zone that communicates with the multi-zone carbon converter slag zone that converts the process feedstock into synthesis gas and slag (however, the carbon conversion zone and the slag zone are separated by an inter-zone region)
A carbon conversion zone consisting of a processing raw material supply port that receives processing raw material from a supply source, a syngas outlet, and an air inlet
Inter-zone region including a barrier that restricts material flow between the carbon conversion zone and the slag zone by partially or intermittently plugging the inter-zone region
A slag zone consisting of a plasma heat source and slag outlet where the raw material is converted into syngas and ash in the carbon conversion zone using the heat from the plasma heat source, and the ash melts in the interzone and / or slag zone Converted to slag.   2. The multi-zone type carbon conversion device according to claim 1, wherein the air supply port is a heated air suction port.   The multi-zone type carbon conversion device according to claim 1, wherein the air supply port is one or a plurality of air boxes.   4. The multi-zone carbon conversion device according to claim 1, 2, or 3, wherein the barrier is a solid precast heat-resistant dome installed in an inter-zone region using four wedge-shaped heat-resistant bricks. The size is such that a groove or space is formed between the inner wall and the dome.   5. The multi-zone carbon conversion apparatus according to claim 4, wherein the chamber is a cylindrical chamber in a substantially vertical direction, and the inter-zone region forms a constricted portion of the chamber.   In the multi-zone type carbon conversion device according to claim 5, the slag zone becomes narrower toward the conical slag discharge port.   4. The multi-zone carbon conversion device according to claim 1, 2, or 3, wherein the barrier is a grate.   In the multi-zone type carbon conversion device according to any one of claims 1 to 7, the inter-zone region further includes a heat transfer element that transfers plasma heat from the slag zone to the inter-zone region.   1-8, any multi-zone carbon converter of any claim further includes a control system.   The multi-zone type carbon conversion apparatus according to any one of claims 1 to 9 further includes a processing raw material pretreatment module.   The multi-zone carbon conversion device according to any one of claims 1 to 10 further includes a slag cooling module.   1 to 11, the multi-zone type carbon converter according to any claim, the plasma heat is a plasma torch.