MX2008014166A - A heat recycling system for use with a gasifier. - Google Patents

Abstract

The present invention provides a system that recycles heat recovered from hot products of a carbonaceous feedstock gasification process back into the gasification process. The hot gaseous products are used to heat working fluids such as air and water to produce hot air, hot water or steam. The heated fluids are used to return heat back to the gasification process. The system also comprises a control system to optimize the efficiency of a gasification process by minimizing energy consumption of the process, while also maximizing energy production.

Description

HEAT RECYCLING SYSTEM FOR USE WITH A GASIFIER FIELD OF THE INVENTION This invention relates to the gasification of a coal feedstock, and in particular to a system that recovers the heat generated by the gasification and recycling process for its use within the system and optionally for external applications.

BACKGROUND OF THE INVENTION Gasification is a process that allows the conversion of coal feed streams, such as municipal solid waste (MS) or coal, into a combustible gas. The gas can be used to generate electricity, steam, or as a basic raw material to produce chemicals and liquid fuels. Possible uses for the gas include: combustion in a boiler for the production of steam for internal processing and / or other external purposes, or for the generation of electricity through a steam turbine; combustion directly in a gas turbine or a gas engine for the production of electricity; fuel cells; the production of methanol and other liquid fuels; as an additional feed load for the production of chemical products such as plastics and fertilizers; the extraction of both hydrogen and carbon monoxide as discrete industrial combustible gases; and other industrial applications. Generally, the gasification process consists of feeding a carbonaceous feed charge into a heated chamber (the gasifier) together with a controlled and / or limited amount of oxygen and optionally water vapor. In contrast to incineration or combustion, which operates with excess oxygen to produce C02, H20, S0X, and NOx, the gasification processes produce a crude gas composition comprising CO, H2, H2S, and NH3. After purification, the primary gasification products of interest are H2 and CO. The useful feed load can include any municipal waste, waste produced by industrial activity and medical waste, drainage, mud, coal, heavy oils, petroleum coke, heavy refinery waste, refinery waste, hydrocarbon contaminated soils, biomass , and agricultural waste, tires, and other hazardous waste. Depending on the origin of the feedstock, volatile compounds may include H20, H2, N2, 02, C02, CO, CH4, H2S, NH3, C2H6, unsaturated hydrocarbons such as acetylenes, defines, aromatics, tars, hydrocarbons (oils) and carbonaceous waste (carbon black and ash). When the feed load is heated, water is the first constituent to evolve. When the temperature of the dry feed load is increased, pyrolysis takes place. During pyrolysis, the feedstock is thermally decomposed to release tar, phenols, and light volatile hydrocarbon gases while converting the feedstock to carbonaceous residue. The carbonaceous waste comprises the residual solids consisting of organic and inorganic materials. After pyrolysis, the carbonaceous residue has a higher concentration of carbon than the dry feedstock and can serve as a source of activated carbon. In gasifiers operating at a high temperature (> 1, 200 ° C) or in systems with a high temperature zone, the inorganic mineral matter is melted or vitrified to form a glass-like molten substance called slag. Since the slag is in a fused, vitrified state, it is usually found to be non-hazardous and can be disposed of in a sanitary landfill as a non-hazardous material, or sold as an iron ore, base material for roads or other construction material . It is becoming less desirable to dispose of the waste material by incineration due to the extreme waste of fuel in the heating process and the additional waste of disposing, as a residual waste, material that can be converted as a useful synthesis gas and solid material. The means to achieve a gasification process vary in many ways, but are based on four key engineering factors: the atmosphere (oxygen content level or air or water vapor) in the gasifier; the design of the gasifier; the means of internal and external heating; and the operating temperature for the process. Factors that affect the gas quality of the product include: composition of the feedstock, preparation and particle size; heating speed of the gasifier; residence time; the configuration of the plant including whether it employs a dry feed or thick solution feed system, the reactive feed-feed flow geometry, the design of the slag ore or dry ash removal system; whether it uses direct or indirect heat generation and the transfer method; and the synthesis gas purification system. Gasification is usually carried out at a temperature in the range of about 650 ° C to 1200 ° C, either under vacuum, at atmospheric pressure or at pressures of up to about 100 atmospheres. There are several systems that have been proposed to capture the heat produced by the gasification process and use such heat to generate electricity, generally known as combined cycle systems. The energy in the product gas coupled with substantial amounts of recoverable sensible heat produced by the process and throughout the gasification system can generally produce enough electricity to move the process, thereby relieving the expense by local electricity consumption. The amount of electrical energy that is required to gasify a ton of a carbonaceous feed charge directly depends on the chemical composition of the feedstock. If the gas generated in the gasification process comprises a wide variety of volatile compounds, such as the type of gas that tends to be generated in a low temperature gasifier with a "low quality" carbonaceous feed charge, it is generally referred to as a gas. of exit. If the characteristics of the feedstock and the conditions in the gasifier generate a gas in which CO and H2 are the predominant chemical species, the gas is referred to as synthesis gas. Some gasification facilities employ technologies to convert raw exhaust gas or pure synthesis gas to a more refined gas composition prior to cooling and cleaning to through a system for conditioning the quality of gas. The use of plasma heating technology to gasify a material is a technology that has been used commercially for many years. Plasma is a high-temperature luminous gas that is at least partially ionized, and is made up of gas atoms, gas ions, and electrons. Plasma can be produced with any gas in this way. This gives excellent control over the chemical reactions in the plasma since the gas could be neutral (eg, argon, helium, neon), reductive (eg, hydrogen, methane, ammonia, carbon monoxide), or oxidant (eg. example, oxygen, carbon dioxide). In the volume phase, a plasma is electrically neutral. Some gasification systems employ plasma heat to drive the gasification process at an elevated temperature and / or to refine the exit gas / synthesis gas when converting, reconstituting, or reforming longer chain volatiles and tars into smaller molecules with or without the addition of other inputs or reagents when the gaseous molecules come into contact with the heat of the plasma, they will dissociate into their constituent atoms. Many of these atoms will react with other input molecules to form new molecules, while others can recombine with themselves. Whenthe temperature of the molecules in contact with the plasma heat decreases; all the atoms recombine completely. Since the input gases can be controlled stoichiometrically, the exhaust gases can be controlled to, for example, produce substantial levels of carbon monoxide and non-substantial levels of carbon dioxide. The very high temperatures (3000 to 7000 ° C) that are achieved with the plasma heating allow a high temperature gasification process where virtually any incoming feed charge can be accommodated including waste in conditions as received, including liquids, gases , and solids in any form or combination. The plasma technology can be located inside a primary gasification chamber to make all the reactions happen simultaneously (high temperature gasification), it can be placed inside the system to make them happen in sequence (low temperature gasification with high refining) temperature), or some combination thereof. The gas produced during carbonaceous feed charge gasification is usually very hot but may contain small amounts of undesirable compounds and requires additional treatment to convert it into a useful product. Once a material carbonaceous is converted to a gaseous state, undesirable substances such as metals, sulfur compounds and ash can be removed from the gas. For example, dry filtration systems and wet scrubbers are often used to remove particulate matter and acid gases from the gas produced during gasification. Various gasification systems have been developed which include systems for treating the gas produced during the gasification process. These factors have been taken into account in the design of several different systems which are described, for example, in the U.S. patent. Nos. 6,686,556, 6,630,113, 6,380,507; 6,215,678, 5,666,891, 5,798,497, 5,756,957, and the patent applications of E.U.A. Nos. 2004/0251241, 2002/0144981. There are also several patents that refer to different technologies for the gasification of mineral coal for the production of synthesis gases for use in various applications, including the U.S. patent. Nos. 4,141,694; 4,181,504; 4,208,191; 4,410,336; 4,472,172; 4,606,799; 5,331,906; 5, 486, 269, and 6, 200, 430. The systems and previous processes have not adequately addressed the problems that must be dealt with on a continual change basis. Some of these types of gasification systems describe means to adjust the process of generation of a useful gas from the gasification reaction. In this way, it would be a major advance in the art to provide a system that can efficiently gasify carbonaceous feedstock in a manner that maximizes the overall efficiency of the process, and / or the stages comprising the overall process. This background information is provided for the purpose of rendering information considered by the applicant to be of possible relevance to the present invention. Admission is not necessarily intended, nor should it be constructed, that any of the foregoing information constitutes prior art against the present invention.

BRIEF DESCRIPTION OF THE INVENTION This invention provides a system for optimizing the gasified carbonaceous feed charge efficiency by recovering sensible heat from the gasification process and recycling for use within the system and optionally for external applications. This invention provides a system that recycles heat recovered from hot gas, and transfer the recovered heat back to a gasifier. In particular, the system comprises means for transferring the hot gas to a gas-to-fluid heat exchanger, where the heat of the hot gas is transferred to a fluid to produce a heated fluid and a cooled gas, and means for transferring the heated fluid to the gasifier. The heated fluid is passed into the gasifier to provide heat required to conduct the gasification reaction. The heated fluid can also optionally be used to preheat or pre-treat, directly or indirectly, the feedstock to be gasified. According to one embodiment of the invention, the system also comprises a control system comprising sensor elements for monitoring the operating parameters of the system, and response elements for adjusting the operating conditions within the system to optimize the gasification process, where the response elements adjust the operating conditions within the system according to the data obtained from the sensor elements, thus optimizing the efficiency of a gasification process by minimizing the energy consumption of the process, while also maximizing the production of energy. According to one aspect of the invention, a process is provided to improve the efficiency of a gasification process of carbonaceous feed charges by recycling sensible heat from a hot gas produced by the gasification process back into the process of gasification using a gas-to-fluid heat exchanger, the process comprising the steps of passing the hot product gas through the gas-to-fluid heat exchanger, passing the cold fluid through the gas-to-fluid heat exchanger, transferring the heat from the hot product gas to the fluid cooled by means of the gas-to-fluid heat exchanger to produce a cooled product gas that removes the heat exchanger by means of a cooled product gas outlet, and a heated fluid that removes the heat exchanger by means of of a heated fluid outlet, and using the heated fluid to provide heat for the gasification process of carbonaceous feed charges.

BRIEF DESCRIPTION OF THE DRAWINGS These and other aspects of the invention will become more apparent in the following detailed description in which reference is made to the attached figures 1 to 14. Figure 1 is a block flow diagram of a system for recycling heat recovered from a hot gas product from a gasification process back to a gasifier, according to one embodiment of the present invention. Figure 2 is a block flow diagram of the heat recovery of the gas product from the process of gasification using a heat exchanger and a heat recovery water vapor generator, according to one embodiment of the present invention. Figure 3 is a block flow diagram of a system for cooling hot gas products, including a heat exchanger for heat recovery of the gas product from the gasification process, and an off stage for cooling additional product gas, according to one embodiment of the present invention. Figure 4A is a schematic diagram showing the functional requirements for a gas-to-air heat exchanger, according to one embodiment of the present invention. Figure 4B is a schematic diagram describing a gas-to-air heat exchanger, according to an embodiment of the present invention. Figure 5 is a schematic diagram describing a gas-to-air heat exchanger, according to an embodiment of the present invention. Figure 6 is a schematic diagram of a converter and its various inputs, according to one embodiment of the present invention. Figure 7 is a schematic diagram describing possible end uses of the exchange water vapor produced by the heat recovery of a product gas in a heat recovery water vapor generator, according to various embodiments of the present invention. Figure 8 is a schematic diagram showing a pipe system for transferring the exchange air to the converter, according to an embodiment of the present invention. Figure 9 is a schematic diagram describing a high level concept of various temperature controls within the system, according to one embodiment of the present invention. Figure 10 is a schematic diagram showing a top-level view of a gas pressure / flow control subsystem, according to an embodiment of the present invention. Figures 11A through 111 are block flow diagrams describing introductions of various embodiments of the present invention. Figure 12 is a cross-sectional view through a mode of a gasifier, detailing the feed charge inlet, gas outlet, solid waste outlet, and the location of air exchange inlets, in accordance with a embodiment of the present invention. Figure 13 is a central longitudinal cross-sectional view through a mode of a gasifier, which details the input of the power load, gas outlet, and the location of air boxes. Figure 14 details the assembled air box of the gasifier illustrated in Figure 13.

DETAILED DESCRIPTION OF THE INVENTION Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. As used herein, the term "about" refers to a variation +/- 10% of the nominal value. It will be understood that such variation is always included in any given value provided herein, whether or not it specifically refers to it. For the purposes of the present invention, the term synthesis gas (or synthesis gas) refers to the product of a gasification process, and may include carbon monoxide, hydrogen, and carbon dioxide, in addition to other gaseous components such as methane, nitrogen and water vapor. As used herein, the term "exchange air" refers to the air after it has been heated using sensible heat of the product gas using a gas to air heat exchanger according to the present invention. Hot gases other than air are included within the scope of the present invention, including, but not limited to, oxygen or enriched air, using the system as described herein. As used herein, the term "converter" refers to an apparatus for converting carbonaceous feedstocks into a crude synthesis gas product, also referred to as a product gas. The converter includes the gasifier and the plasma gas reformer. As used herein, the term "(carbonaceous) feedstock" may be any suitable carbonaceous material to be gasified in the current gasification process, and may include, but is not limited to, any of the waste materials, carbon mineral (including high-sulfur, lower-grade mineral coal not suitable for use in coal-fueled power generators), petroleum coke, heavy oils, biomass, drainage, sludge, sludge and paper mills, and agricultural waste. Waste materials suitable for gasification include both hazardous and non-hazardous waste, such as municipal waste, waste produced by industrial activity (paint sludge, non-conforming paint products, wear absorbents), automobile waste, used tires and waste medical, any carbonaceous material unsuitable for recycling, including non-recyclable plastics, drainage mud, coal, heavy oils, petroleum coke, heavy refinery waste, refinery waste, solid waste contaminated with hydrocarbons and biomass, agricultural waste, tires, hazardous waste, industrial waste and biomass. Examples of biomass useful for gasification include, but are not limited to, waste or recent wood, fruit processing residues, vegetables and grains, paper mill waste, straw, turf, and manure. As used herein, the term "product gas" generally means the gas generated by the gasification facility, prior to cooling and cleaning by processes designed to remove contaminants. Depending on the design of the gasification installation, it can be used to refer to, for example, raw outlet gas, crude synthesis gas, reformed exhaust gas or reformed synthesis gas. As used herein, the terms "gas-to-air heat exchanger" and "gas heat exchanger" are interchangeable, and refer to the heat exchanger used to transfer sensible heat from the hot gas product to the air. A "sensor element" is defined to describe any element of the system configured to register a characteristic of a process, a process input or process output, where such a characteristic can be represented by a characteristic value that is used in the monitoring, regulation and / or control of one or more processes local, regional and / or global system. The sensor elements may include, but are not limited to, sensors, detectors, monitors, analyzers or any combination thereof for recording a temperature, pressure, flow, composition of a process, fluid and / or material and / or other of such characteristics, as well as position and / or arrangement of the material at some given point within the system and any operating characteristic of any process device used within the system. A "response element" is defined to describe any element of the system configured to respond to a registered characteristic in order to operate a process device operatively associated with it according to one or more predetermined or computerized control parameters, wherein one or more control parameters are defined to provide a desired process result. Response elements may include, but are not limited to, conductors, static and / or dynamically variable power sources, inductors, and any other configurable element for impart a physical action to a device based on one or more control parameters. The response elements can be operatively coupled to various process devices, which may include, but are not limited to, material entry mechanisms, plasma heat sources, additive input means, gas blowers, additive inlet blowers. , gas flow regulators, additive inlet flow regulators, solid waste conditioner additive input regulators and plasma heat source regulators, and other process devices that operate to affect any local, regional and / or local process global. The present invention provides a system for optimizing the efficiency of the process of gasifying a carbonaceous feedstock into a gaseous product by minimizing the energy consumption of the process while also maximizing the production of energy. In particular, the present invention provides a heat recycling system for use with a gasifier, wherein the sensible heat of the gasification process is efficiently recovered, and wherein the recovered heat is transferred to one or more processes within the system, and optionally to processes outside the system. The system includes a heat exchange system for heat recovery of the product gas hot, where the heat exchanger transfers sensible heat from the product gas to an appropriate fluid. Suitable fluids for the current heat exchange process include, but are not limited to, air, water, oil, or other gas such as nitrogen or carbon dioxide. In particular the system comprises a pipe system for transferring a hot product gas from a gasification process to a gas-to-fluid heat exchanger, where the heat of the hot product gas is transferred to a fluid to produce a heated fluid and a product gas cooled. The system further comprises another pipe system for transferring the heated fluid to the gasification process. In one embodiment, the gas-to-fluid heat exchanger is a gas-to-air heat exchanger, where the heat is transferred from the product gas to the air to produce a heated exchange air. In one embodiment, the gas-to-fluid heat exchanger is a heat recovery water vapor generator, where the heat is transferred to the water to produce heated water or water vapor. In accordance with one embodiment of the present invention, as schematically described in Figure 1, a heat recycling system 5000 is provided to transfer the heat produced during a heat transfer process. gasification again to a converter 1000 to drive the gasification reaction. In this embodiment, this is done by heating the air 5010 with the heat of a hot product gas 5020 produced in a converter 1000 in a gas-to-air heat exchanger 5100 to produce a heated air product (hereinafter referred to as air). 5015) and a cooled product gas 5025, and pass the heated exchange air 5015 back to the interior of the converter 1000. The energy efficiencies are therefore optimized by this system, since the recycling of sensible heat recovered again The gasification process reduces the amount of energy expenditure required from external sources for the drying, volatilization and gasification stages of the feed load. The recovered sensible heat can also serve to minimize the amount of plasma heat required to achieve a defined product gas quality. In this manner, the present invention allows the efficient gasification of a carbonaceous feed charge, wherein the heat required for gasification is provided by hot exchange air, where the exchange air has been heated using sensible heat recovered from the hot product gas . The sensible heat transferred from the product gas to the heated exchange air can also be used to external heating applications, as well as heating applications elsewhere in the gasification process. For example, the heated exchange air can be used directly or indirectly to preheat or pre-treat the feedstock to be gasified. In the case of a direct pre-treatment / heating stage, the exchange air is passed directly through the feed charge to heat and / or remove the moisture. In the case of a direct pre-treatment / heating stage, the heat is transferred from the heated exchange air to the oil (or to the water to produce water vapor), where the heated oil (or steam product) is used to Heat the dryer wall / feed charge preheater. In all cases, sensible heat recycling minimizes the amount of energy expended required for these heating applications. It is therefore within the scope of the present invention to transfer the heat of the heated exchange air to any working fluid of interest. Such working fluids of interest include, but are not limited to, oil, water, or other gas such as nitrogen or carbon dioxide. Where heat is transferred to a working fluid other than air, an appropriate heat exchange system is used.

After the heat is recovered in the gas-to-air heat exchanger, the product gas, although cooled, can still contain a lot of heat to undergo filtering and conditioning steps as is known in the art. The present invention therefore also optionally provides additional cooling of the product gas before the subsequent filtering and conditioning steps. In the embodiment described in Figure 2, the. heat recycling system 5001 heats the air 5010 with the heat of a hot product gas 5020 in a gas-to-air heat exchanger 5102 to produce a heated air product (hereinafter referred to as exchange air 5015) and a gas partially cooled product 5023, and pass the heated exchange air back into the converter 1000. The heat recycling system 5001 also includes a subsystem to recover additional heat from the partially cooled product gas 5023 after it is passed through the exchanger heat-to-air heat 5102. In this manner, the system 5001 further comprises a heat recovery steam generator 5302, hence the additional heat recovered from the product gas is used to convert water 5030 to water vapor (referred to as exchange water vapor 5035), therefore a product gas completely cooled product 5025. The exchange water vapor produced in the heat recovery water vapor generator can be used to drive downstream power generators such as steam turbines and / or used in condition turbines direct and / or can be added to the gasification process. The exchange water vapor can also be used in other systems, for example, for the extraction of oil from tar sands or in local heating applications, or it can be supplied to local industrial customers for their purposes. In one embodiment, the water vapor produced using heat from the product gas is saturated water vapor. In another embodiment, the water vapor produced using heat from the product gas is superheated water vapor, which can be produced either directly through heat exchange between water and product gas or between saturated steam and product gas. The system of the present invention is for use with a converter in which the feed charges are converted (by means of exit gas intermediates) to a crude, hot gaseous product. A typical converter for use with this invention comprises a feed charge input for input of the feed charge to be gasified, one or more air exchange inputs to provide heated exchange air to drive the gasification process, a hot product gas outlet, and optionally one or more process additive inlets. The converter also comprises one or more plasma heat sources for converting the exit gas intermediaries from the gasification process to the raw product gas. Where the system does not include a system for recovering additional heat from the partially cooled product gas after it is passed through the gas-to-air heat exchanger, another system for further cooling the product gas before conditioning can be provided. In one embodiment, as described in Figure 3, the system 5003, in addition to cooling the hot product gas 5020 in the gas-to-air heat exchanger 5103 to produce a partially cooled product gas 5023 and heating the exchange air 5015, also it comprises a dry-off stage 6103 to further cool the product gas before conditioning. The dry-off stage is provided to remove excess heat from the product gas by the addition of a controlled amount of atomized water 6030 to provide a cooled product gas 5025 as may be required for the subsequent filtering and conditioning steps. The selection of an appropriate system for additional cooling of the product gas before conditioning is within the knowledge of a person skilled in the art.

According to one embodiment of the present invention, the current system also comprises a control subsystem comprising sensor elements for monitoring system operating parameters, and response elements for adjusting operating conditions within the system to optimize the gasification process, where the response elements adjust the operating conditions within the system according to the data obtained from the sensor elements, therefore optimizing the efficiency of a gasification process by minimizing the energy consumption of the process, while also maximizing the production of energy. The control subsystem can also be used to optimize the composition (ie, calorific value) of the product gas produced, and optionally to ensure that the system remains within safe operating parameters.

Heat Exchangers The present invention provides a system for transferring the heat produced during the gasification process back to a gasifier to conduct the gasification reaction. This can be achieved by recovering sensible heat from the hot product gas using a heat exchange system (for example, a gas to fluid heat exchanger) to transfer the heat of the product gas to an appropriate working fluid, thereby producing a heated fluid and cooled product gas. In one embodiment, the heated fluid produced in the gas to fluid heat exchanger is passed back into the gasifier. In one embodiment, the gas to fluid heat exchanger comprises one or more gas-to-air heat exchangers. The functional requirements for a gas-to-air heat exchanger are shown in Figure 4A, where the hot product gas 5020 and the air 5010 each are passed through the gas-to-air heat exchanger 5104A, therefore the sensible heat is transferred. of hot product gas 5020 to air 5010 (blown by a process air blower 5012) to provide a heated exchange air 5015 and a cooled product gas 5025. Different kinds of heat exchangers can be used in the current system, including heat exchangers. envelope and tube heat, both single-pass, straight and multi-pass design, U-tube design, as well as plate-type heat exchangers. The selection of appropriate heat exchangers is within the knowledge of a technician of ordinary skill in the art.

Some particulate matter is present in the product gas, so the gas-to-air heat exchanger is designed specifically for a high level of particulate loading. The pertule size is typically between 0.5 to 100 microns. In a modality described in Figure 4B, the heat exchanger is single pass vertical flow heat exchanger 5104B, where the product gas 5020 flows on one side of the tube and the air 5010 flows on the side of the enclosure. In the single-pass vertical flow mode, the product gas 5020 flows vertically in a "one-step" design, which minimizes areas where a construction or erosion of particulate material could occur. The velocities of the product gas must be maintained to be high enough to self-clean, while erosion is still minimized. In one embodiment, the gas velocities are between 3000 to 5000 m / min. Under normal flow conditions, the gas velocities are from about 3800 m / min to about 4700 m / min. Due to the important difference in the air inlet temperature and hot product gas, each tube in the gas-to-air heat exchanger preferably has a single expansion bellows to prevent rupture of the tube. The rupture of the tube can be presented where a single tube is covered and therefore does not expand / contract more with the rest of the tube bundle. In those modalities where the process air pressure is greater than the pressure of the product gas, the rupture of the tube presents a high risk due to the problems that result from the air entering the gas mixture. In one embodiment of the present invention, the system runs intermittently, i.e., undergoes numerous on-off cycles as desired. Therefore, it is important that the equipment is designed to withstand repeated thermal expansion and contraction. In order to minimize the hazardous potential of a pipe leak, the system of the present invention further comprises one or more individual temperature transmitters, as described in Figure 5, located, for example, temperature transmitters 5581 at the input of the product gas 5521 and temperature transmitters 5582 at the product gas outlet 5526 of the gas-to-air heat exchanger, as well as 5583 temperature transmitters at the exchange air outlet 5517. Where a temperature transmitter is associated with the gas outlet product 5526 of the gas-to-air heat exchanger 5105, the temperature transmitter is placed to detect an increase in temperature that results from combustion in the event that there is an exchange air leak inside the Gas pipe product. The detection of such a rise in temperature will result in automatic shutdown of the process air blower 5012 so that the source of oxygen is removed. Where a temperature transmitter is associated with the exchange air outlet 5517 of the gas-to-air heat exchanger 5105, this temperature transmitter is used to ensure the exchange air temperature that remains within the set temperature range as required. for the gasification process. In order to avoid providing a lot of heated exchange air (or exchange air that is very hot) to the gasification process, which could result in overheating of the feed load, a 5590 control valve is opened to vent the exchange air in excess to the atmosphere. In addition, heat exchangers are provided, as required, with ports for instrumentation, inspection and maintenance, as well as repair and / or cleaning of the pipes. In one embodiment, the gas-to-fluid heat exchanger is a heat recovery water vapor generator, which utilizes the recovered heat to generate exchange water vapor. In one embodiment, water is provided inside the heat exchanger in the form of steam from low temperature water In another embodiment, the exchange water vapor produced is superheated or saturated water vapor. The exchange water vapor produced in this manner can be used as a process water vapor additive for the gasification process, or used to drive a turbine to produce electricity or drive rotating process equipment, for example, a gas blower . Water vapor that is not used within the conversion process, to produce electricity or to power the rotating process equipment, can be used for other commercial purposes, such as in local heating applications, or to improve the extraction of oil from the tar sands. The exchange water vapor can also be used for an indirectly heated feed charge in a feed charge conditioner, thereby drying the feed charge before gasification in the converter. The heat recovery steam steam generator used in a current system mode is a tube and shell heat exchanger, where the product gas flows vertically through the pipes and the water is boiled on the side of the pipe. envelope The heat exchange system for the Heat recovery water vapor generator is designed with the understanding that some particulate matter will be present in the product gas. Again, product gas velocities are also maintained at a high enough level for self-cleaning of the tubes, while minimizing erosion.

Converters for Use with This System The current system includes a converter to convert the feed load to a gaseous product. This conversion takes place by means of the gasification of the feedstock and the reformulation of the intermediary gaseous products. The gasification stages of the feedstock include: i) drying the feedstock to remove any residual moisture, ii) volatilization of the volatile constituents of the dried feedstock to produce a carbonaceous residue intermediate, and iii) conversion from the carbonaceous residue to exhaust gas and ash. The gaseous products of the gasification process therefore include the volatile constituents and offgas, which are optionally subjected to a reformulation step to provide the gaseous product. In one modality, the reformulation stage is a phase of reformulation assisted by plasma.

The converter therefore comprises a refractory lined chamber having at least one feed charge inlet, one or more air exchange inlets, a gas outlet, and a solid waste outlet. The converter also optionally comprises one or more process additive inputs, and one or more plasma heat sources. In one embodiment, the converter is a horizontally oriented gasifier, where the feed charge enters the gasifier through a feed charge input located at one end of the gasifier. The feed load undergoes gasification as it is transferred to a solid waste outlet located at the opposite end of the gasifier. The gasification process can also be carried out in one of a variety of standard cone gasifiers known in the art. Examples of gasifiers known in the art include, but are not limited to, drag flow reactor vessels, fluidized bed reactors, and rotary kiln reactors, each of which is adapted to accept feed charge in the form of solids. , in particles, thickened mixture, liquids, gases, or a combination thereof. The gasifier can have a wide range of length-to-diameter ratios and can be oriented either vertically or horizontally.

In each of these embodiments, the gasification process is facilitated by the introduction of a heated fluid through appropriately adapted heated fluid inlets, in accordance with the present invention. In one embodiment, the gasification process is facilitated by the introduction of heated exchange air through exchange air inlets. In accordance with the present invention, the heated fluid can be supplied as required to different regions of the gasifier through independent heated fluid feed and distribution systems. In one embodiment, the heated fluid feed and distribution systems comprise exchange air inlets that allow the introduction of heated exchange air to the gasification region. These inputs are placed inside the converter to distribute the heated exchange air along the converter to start and conduct the gasification of the feed load. In one embodiment, the exchange air inlets comprise perforations located in the floor of the gasifier. In one embodiment, the exchange air inlets comprise perforations located in the walls of the gasifier. In one embodiment, the air inlets of Exchange comprises separate air boxes for each region through which the hot exchange air can pass through perforations in the converter floor to such a region. In a modality, the exchange air inlets are independently controlled sprinklers for each region Optionally, to avoid blockage of exchange air inlets during processing, the size of the inlet hole is selected in such a way as to create a restriction and thus a pressure drop around each hole. This pressure drop is sufficient to prevent waste particles from entering the inlet holes. The inlet holes can optionally be plugged out towards the top face to exclude particles from becoming clogged in the hole. The converter can be designed in such a way that the process for converting the feedstock to a product gas (i.e., the gasification and reformulation stages) both generally take place in a single region, or chamber, within the system. The converter can also be designed in such a way that the product gas feed charge conversion process takes place in more than one region, that is, where the gasification and reformulation stages are carried out. they separate to some extent from one another and take place in discrete regions within the system. In these types of converters, the process occurs either in more than one region within a chamber, in separate chambers or some combination thereof, wherein the regions are in fluid communication with one another. In a multiple region converter, a first, or primary, region or chamber (also referred to as a gasifier) is used to heat the feed charge to dry the feed charge (if residual moisture is present), extract the volatile constituents from the feed. Feeding charge, and converting the resulting carbonaceous residue to a gaseous product and ash, thereby producing an output gas product, while a second region or chamber (also referred to as a reformulator) is used to apply plasma heat and other additives of process (for example, air and / or water vapor) to ensure the complete conversion of the exhaust gas and volatiles to the interior of a product gas. Where two or more different regions or chambers are used for the gasification of the feedstock and the conversion of the outlet gas to the product gas, the gas leaving the final region of the converter is the product gas. In one embodiment, different stages of the gasification process can take place in regions different from the gasifier. One skilled in the art would appreciate that conceptually, conditions in the gasifier at any location could be optimized in response to the nature of the feed loading material at that particular location by segregating the gasifier to an interior of an infinite number of regions. The practical modality of this concept, however, is to segregate the gasifier within a finite number of optimized regions in response to the characteristics of the general or average feed load material of a larger area. It would be apparent to a person skilled in the art that the gasifier may therefore segregate into two, three, four or more regions depending on the characteristics of the feed load. In accordance with one embodiment of the present invention, each step of the gasification process is facilitated by the introduction of an appropriate amount of heated exchange air through appropriately adapted air exchange inlets. The feed load is introduced through one or more feed charge inputs, which are arranged to provide optimum exposure of the feed load to the heated exchange air, or other heated fluids, for a complete and efficient conversion of the load of feed to the gaseous product.

In one embodiment, the current system allows the condition of a high carbon feed load (HCF), such as crushed plastic, either in combination with the feed load before the introduction to the converter, or through a dedicated HCF input, thereby allowing a rapid response to the process demands for upper or lower carbon input to meet the required gas quality. The optional inputs of process additives provide the addition of gases such as oxygen, air, air enriched with oxygen, steam or other gases useful for the gasification process, inside the converter. Process additive inlets may include air inlet ports, water vapor inlet ports, exchange air inlet ports, and exchange water vapor inlet ports. These ports are positioned inside the converter for the optimal distribution of process additives along these. The water vapor additives can be provided by a heat recovery steam generator. Oxygen in the exchange air is also used to balance the chemistry to produce the required product gas and remove the maximum amount of carbon. Oxygen also initiates or increases the ratio of the exothermic reactions that produce carbon monoxide, carbon dioxide, hydrogen and other large particles of hydrocarbons. The heat of the exothermic reactions, together with the heat provided by the heated exchange air and / or other heated fluid, together increase the processing temperature in the converter. Figure 6 is a schematic diagram summarizing the various inputs and outputs associated with a mode of a converter for use with the system of the present invention. This embodiment is a converter 1006 comprising a horizontally oriented gasifier 2006 having a feedstock input 2604, wherein the feedstock comprises a combination of MSW municipal solid waste and a high HCF carbon feedstock (such as plastic). ). The converter 1006 has multiple air exchange inputs 2619A, 2619B and 2619C located to provide the exchange air 5015 as required for the gasification reaction. The converter also has 3616 air exchange inlets and 3630 water vapor inlets next to the plasma torches 3008 to provide air and water vapor additives as required for the reformulated reaction of the plasma. The converter 1006 has a solid waste outlet 2608 in communication with a solid waste conditioning chamber 4620. The material moves laterally through the gasifier in order to facilitate the specific stages of the gasification process (drying, volatilization, conversion of carbonaceous residue to ash). This lateral movement of the material through the gasifier is carried out by means of the use of one or more side transfer units, which may include, but are not limited to, a moving shelf, movable platform, drive plunger, router brush, element screw or conveyor belt. One or more lateral transfer units can act in a coordinated manner or individual lateral transfer units can act independently. In order to optimize the control of the flow rate of the material and the height of the stack, the individual lateral transfer units can be moved individually, at varied speeds, at varied movement distances, at varied movement frequencies. The lateral transfer units must be able to operate effectively in the severe conditions of the gasifier and in particular it must be capable of operating at elevated temperatures. The converter is coated with a refractory material that can be one or a combination of conventional refractory materials known in the art that are suitable for use in a container for non-pressurized reaction at high temperature (for example, at a temperature of about 1100 ° C to 1400 ° C). Examples of such refractory materials include, but are not limited to, high temperature calcined ceramics (such as aluminum oxide, aluminum nitride, aluminum silicate, boron nitride, zirconium phosphate, chromium oxide), glass brick ceramic and high alumina containing mainly silica, alumina and titania. The solid waste outlet is located to allow the removal of the solid produced from the gasification reaction of the converter. The solids produced from the gasification process, also referred to as solid waste, may take the form of the carbonaceous residue, ash, slag, or some combination thereof, which is removed, either continuously or intermittently, from the converter through appropriately adapted outlets. The carbonaceous residue can either be removed before to complete the conversion to the gaseous product, or it can remain in the gasifier during the additional conversion to the ash. The product ash is then removed through the solid waste outlet, towards, for example, an ash collection chamber, or optionally to a solid waste conditioning chamber for further processing. The appropriate design and location of the solid waste disposal output in the converter is selected using the knowledge of a technician expert in the revealing technique, according to the requirements of the system and the type of production is eliminated. The solid waste outlet is generally disposed at or near the bottom of the chamber to allow the waste to be passively removed, using gravity flow. Some systems optionally employ a solid waste disposal system to actively transport the waste from the bottom of the converter. Such removal of the active solid residue can be provided by one of a variety of devices known in the art. Examples include, but are not limited to, screws, drive pistons, horizontal rotation vanes, horizontal rotation arms, and horizontal rotation wheels. In those embodiments where the solid waste (eg, ash produced) from the gasification process is further converted to slag, the ash-to-slag conversion takes place in a solid waste conditioning chamber. A plasma heat source can be used in the solid waste conditioning chamber to melt the slag ash. The molten slag, at a temperature of, for example, about 1100 ° C to about 1600 ° C, can be periodically or continuously removed from the solid waste conditioning chamber and then cooled to form a solid slag material. Such slag material can be pretended for disposal in landfills. The solid product can be further broken into the interior in aggregates for conventional uses. Alternatively, the molten slag can be emptied into containers to form metal bars, bricks, tiles or similarly constructed material. Where the solid residue of the gasification process contains some unconverted carbons, the plasma heat of the slag conditioning stage ensures the complete conversion of the unconverted carbon to hot gaseous products having a fuel value. This gaseous product is referred to as the waste gas. In one embodiment, the heat is recovered from the hot waste gas using a dedicated gas-to-air heat exchanger for waste, producing a product of heated air and a cooled waste gas. The cooled waste gas is further optionally conditioned in a dedicated gas conditioning subsystem to produce a product gas that can be combined with the gaseous product of the main gasification process.

System for additional cooled product gas before the conditioning stage The present invention, in addition to an exchanger from heat gas to fluid, optionally includes a system for additional cooling of the product gas before the conditioning stage. In one embodiment, the system for additional cooling of the product gas before cleaning and conditioning is also provided for the recovery of additional heat. Where the additional sensible heat recovery of the product gas is an objective, the heat is transferred from the gas to another working fluid, for example water, oil, or air. The products of such embodiments may include, respectively, heated water (or steam), heated oil, or additional hot air. In one embodiment, the system of the present invention further recovers the sensible heat of the product gas using a heat exchanger to transfer the heat of the partially cooled product gas to water, thereby producing either heated water or steam, and a gas that has cooled down additional. In one embodiment, the heat exchanger employed in this step is a heat recovery water vapor generator, which uses the recovered heat to generate exchange water vapor. In one embodiment, the water is provided to the interior of the heat exchanger in the form of low temperature steam. In another embodiment, the exchange water vapor produced is superheated or saturated water vapor.

Figure 7 describes the relationship between a gas-to-air heat exchanger 5107 and a heat recovery water vapor generator 5307, according to one embodiment of the invention. The exchange water vapor 5035 produced in the heat recovery steam generator 5307 can be used in various downstream applications. Figure 7 describes different possible end uses (label A to G) for the exchange water vapor produced using a heat recovery steam generator, according to various embodiments of the present invention. For example, as described in option D, the exchanged water vapor 5035 can be passed into the converter 1007 as a process steam additive, in one embodiment of the invention. The 5035 exchange water vapor can be used as a steam additive from the process during the gasification process to ensure sufficient oxygen and free hydrogen to maximize the conversion of the feed charge into the product gas. The use of water vapor as a process additive containing oxygen is preferred due to its low cost and easy handling. Water vapor also includes hydrogen, which can be a desired product of the gasification process. The exchange water vapor also produced it can be passed through a turbine 5715, thereby driving the rotating process equipment, for example, an exchange air blower 5712 (option B), or a product gas blower 5722 (option C). Water vapor that is not used within the conversion process or to drive the rotating process equipment can be used for other commercial purposes, such as the production of electricity through use. of a 5705 water vapor turbine (option A), or in local heating applications 5710 (option E) or can be supplied to local industrial customers for their purposes, or they can be used to improve oil extraction from tar sands 5780 (option F). The exchange water vapor can also be used for the heat supply charge indirectly in a 5767 feed charge conditioner, thereby drying the feed charge before gasification in the converter (option G). In an embodiment where the system for additional cooling of the product gas before conditioning does not include the recovery of additional heat, the cooling stage comprises a dry-off stage, wherein the temperature of the product gas is reduced by direct controlled injection (saturation). adiabatic) of atomized water.

In a modality, where the cooling of different systems or processes is required, the excess heat can be removed (and recovered) by a water cooling stage. The resulting heated water can, in turn, be used for heat working fluids for use on either side in the gasification process. The heated water streams come from various sources including, but not limited to, gas cooling processes in the gas conditioning system or plasma heat source cooling systems. The heated water can also be used to preheat the oil for various applications.

Pipe systems Pipe systems are used to transfer gases from one component of the system to another. In this way, the system comprises a product gas pipe system for transferring the hot product gas product to a heat exchanger for sensible heat recovery. The system also comprises an exchange air pipe system for transferring the heated exchange air to the converter, where it is introduced to the converter by means of air exchange inputs. Pipe systems typically employ one or more pipes, or lines, through which gases are transported.

Where the system comprises a steam generator with heat recovery, the system will also comprise an exchange water vapor pipe system for transferring the heated exchange water vapor for use in one or more of the previously listed applications. The interchange water vapor pipe system may comprise multiple pipes running in parallel, or a branched pipe system, where a given branch is designated for a specific application. The materials and specifications in size for the gas lines of the pipe system are selected as required to provide safety and efficient transportation of the gas. Where the gas being transported is the product gas of high temperature, the design of the thickness and type of refractory used is selected to ensure that the protected wall temperature is around 200 ° C in order to remain above the gas dew point acid to prevent corrosion. In one embodiment, the hot product gas lines are made of carbon steel and refractory coated. In one embodiment, the heated exchange air lines comprise stainless steel pipes. In order to maximize the amount of sensible heat that can be recovered from the hot product gas, or to minimize the cooling of the heated exchange air or exchange water vapor, the pipe system is optionally provided with a means to minimize the loss of heat to the surrounding environment. The heat loss can be minimized, for example, through the use of an insulation barrier around the pipes, which comprises insulated materials as are known in the art and when designing the plant to minimize the lengths of the pipes. This is particularly important for high temperature pipes. In one embodiment, the heated exchange air leaves the gas-to-air heat exchanger in a single pipe, which is then divided into several smaller diameter pipes in order to provide the heated exchange air for different regions of the converter as is required Each branch of the pipe system includes an air flow control valve to control the flow of heated air for the different regions of the converter as required. The product gas piping system optionally employs one or more flow regulating devices and / or blowers located throughout the system to provide a means to direct the flow rate of the gaseous product. The exchange air pipe system Optionally, it will use one or more flow regulating devices, flow meters and / or blowers, located throughout the system as required to control the flow rate of the exchange air. In one embodiment, as described in FIG. 8, the exchange air flow control valves 5890A, 5890B and 5890C are provided to control the exchange air flow 5015 for each level of the gasification region. The control valves control the exchange air flow for the air inlets 2812, 2814, and 2816 for the 2008 gasifier. In one embodiment, the 5890A, 5890B, and 5890C control valves are independently controllable to regulate the air quantity of the air. exchange 5015 that is introduced to each region of the gasifier. In one embodiment, there is an exchange air flow control valve 5892 for controlling the exchange air flow for the reformer 3008. In this embodiment, the exchange air is provided as a process additive. The exchange air pipes also optionally comprise means for diverting the exchange air, for example, for ventilation outlets or for optional additional heat exchange systems. The devices that regulate the flow, and / or Blowers, and / or biasing means are optionally controlled by a control subsystem, as discussed in detail below. The pipe system will also optionally comprise service ports to provide access for the system for the purpose of carrying routine maintenance, as well as repair and / or cleaning of the pipes.

Plasma heating sources The system of the present invention employs one or more plasma heat sources to convert the exhaust gas produced by the gasification process to the product gas. Plasma heat sources are also provided in the solid waste conditioner to melt and condition the solid waste. A variety of commercially available plasma heat sources which can adequately develop high flame temperatures for sustained periods at the point of application can be used in the system. In general, such plasma heat sources are available in sizes from about 100 kW to 6 MW in output power. Plasma heat sources can employ one, or a combination, of suitable working gases. The examples of suitable working gases they include, but are not limited to, air, argon, helium, neon, hydrogen, methane, ammonia, carbon monoxide, oxygen, nitrogen, and carbon dioxide. In an embodiment of the present invention, the plasma heat source is operated continuously using air as the plasma medium to produce a temperature in the gasifier in excess of about 900 to about 1300 ° C as required to convert the output gas to the product gas. In this regard, a number of alternative plasma technologies are suitable for use in the current system. For example, it is understood that non-transferred arc torches and transferred arc torches (both AC and DC), using appropriately selected electrode materials, can be employed. It is also understood that inductively coupled plasma (ICP) torches can also be employed. The selection of an appropriate plasma heat source is within the ordinary skill of one skilled in the art. In one embodiment of the present invention, one or more plasma heat sources will be positioned to optimize the conversion of the exit gas to the product gas. The position of one or more plasma heat sources is selected according to the design of the gasification system, for example, according to whether the system employs a one-stage or two-stage gasification process. By example, in one embodiment employing a two-stage gasification process, the plasma heat source may be arranged in a position relative to, and accurate in the direction of, the entry through which the exit gas enters the chamber of reformulation, or reformulation area. In these embodiments employing a one stage gasification process, one or more plasma heat sources may extend towards the gasifier core. In all cases, the position of the plasma heat sources is selected according to the requirements of the system, and for the optimum conversion of the output gas to the product gas. In one embodiment, the heat of plasma used in the plasma reformulator is provided by a non-transferred DC arc. In one embodiment, the plasma heat sources are located adjacent to one or more air inlet ports and / or water vapor such that the air and / or water vapor additives are injected into the path of the plasma discharge of the plasma heat source. In a further embodiment, the plasma heat sources can be moved, fixed or a combination thereof. In one embodiment, the plasma heat used in the solid waste conditioner is provided by a Arc torch not transferred DC. In another embodiment, the plasma heat used in the solid waste conditioner is provided by a DC transfer arc torch.

Control system In order to optimize the efficiency of the present invention, a system is also optionally provided to control the conditions under which the current process is carried out, as well as the operating conditions of the system according to the present invention. Where the end use of the gas product is to generate electricity, the control subsystem also provides optimal energy production by ensuring that the gas composition and pressure are maintained within the tolerances of the gas engines / generators used to produce the electricity . In one embodiment of the present invention, a control system may be provided to control one or more processes implemented in, and / or by, the various systems and / or subsystems described herein, and / or provide control of one or more process devices contemplated herein to affect such processes. In general, the control system can operationally control several local and / or regional processes related to a given system, subsystem or component of them, and / or related to one or more global processes implemented within a system, such as a gasification system, within or in cooperation with which the various embodiments of the present invention can be operated, and thereby adjust the various control parameters of the same adapted to affect these processes for a defined result. Various sensor elements and response elements can therefore be distributed throughout the distributed system (s), or in relation to one or more components thereof, and used to acquire various process, reactive and / or product characteristics, comparing these characteristics with suitable intervals of such characteristics that lead to achieving the desired result, and respond by implementing changes in one or more of the continuous processes by means of one or more controllable process devices. The control system generally comprises, for example, one or more sensor elements for recording one or more characteristics related to the system (s), process (s) implemented therein, input (s) provided thereby, and / or output (s) generated by it. One or more computing platforms are linked communicatively to these sensor elements to access a characteristic value representative of the registered characteristic (s), and configured to compare the characteristic value (s) with a predetermined range of such defined values to characterize these characteristics as appropriate for the selected operating and / or downstream results, and calculate one or more process control parameters that lead to maintaining the characteristic value with this predetermined interval. A plurality of response elements can thus be operatively linked to one or more operable process devices to affect the system, process, input and / or output and thereby adjust the registered characteristic, and communicatively linked to the computing platform (s) for access the calculated process control parameters and operate the process device (s) accordingly. In one embodiment, the control system provides feedback, advance and / or predictive control of various systems, processes, inputs and / or outputs related to the conversion of coal feed streams into a gas, in order to promote an efficiency of one or more processes implemented in relation to it. For example, various process characteristics can be evaluated and controllably adjusted to influence these processes, which may include, but are not limited to, the calorific value and / or composition of the feed load, the characteristics of the product gas (for example calorific value, temperature, pressure, flow, composition, carbon content, etc.), the degree of variation allowed for such characteristics, and the cost of the inputs versus the value of the outputs. Continuous and / or real-time adjustments to various control parameters, which may include, but are not limited to, power of the heat source, feed additive ratio (s) (eg, oxygen, oxidants, steam, etc.). water, etc.), feeding charge feed ratio (s) (eg one or more different and / or mixed feeds), system / gas flow / pressure regulators (e.g. blowers, relief valves and / or control, high burners, etc.), and the like, can be executed in a way by which one or more characteristics related to the process are evaluated and optimized according to the design and / or specifications below. Alternatively, or in addition to this, the control system can be configured to monitor the operation of the various components of a given system to ensure proper operation, and optionally, to ensure that the process (s) implemented thereby are within regulatory standards, when they apply such standards. According to one embodiment, the control system can also be used to monitor and control the total energy impact of a given system. For example, a given system can be operated such that the energy impact thereof, or minimized again, for example, by optimizing one or more of the processes implemented with it, or again by increasing the energy recovery (for example heat spent) generated by these processes. Alternatively, or in addition to this, the control system can be configured to adjust a composition and / or other characteristics (eg temperature, pressure, flow, etc.) of a product gas generated by means of the controlled process (s) such that such characteristics are not only suitable for downstream use, but also substantially optimized for efficient and / or optimal use. For example, in a modality where the product gas is used to drive the gas engine of a given type for the production of electricity, the characteristics of the product gas can be adjusted such that these characteristics better match the optimum input characteristics for such engines. . In one embodiment, the control system can be configured to adjust a given process in such a way that limitations or performance guidelines with respect to residence times of reactant and / or product in various components, or with respect to various processes of the process global are met and / or optimized. For example, you can control the speed of an upstream process of way to substantially coincide with one or more downstream processes. In addition, the control system can, in various modalities, be adapted for the sequential and / or simultaneous control of various aspects of a given process in a continuous and / or real-time manner. In general, the control system can comprise any type of control system architecture suitable for the application at hand. For example, the control system may comprise a substantially centralized control system, a distributed control system, or a combination thereof. A centralized control system will generally comprise a central controller configured to communicate with various local and / or remote registration devices and response elements configured to respectively register various features relevant to the controlled process, and respond to it by means of one or more devices of controllable processes adapted to directly or indirectly affect the controlled process. By using a centralized architecture, most of the calculations are implemented centrally by means of a centralized processor or processors, such that most of the hardware and / or software necessary to implement the process control are located in the same location.

A distributed control system will generally comprise two or more distributed controllers which can communicate with respective sensing and response elements to monitor local and / or regional characteristics, and respond to it by means of local and / or regional process devices configured for affect a local process or sub-process. Communication can also take place between the distributed controllers by means of various network configurations, wherein the characteristics recorded by means of a first controller can be communicated to a second controller for response thereto, wherein such distal response can have an impact about the characteristic registered in the first location. For example, a characteristic of a downstream product gas can be recorded by a downstream monitoring device, and adjusted by the setting of a control parameter associated with the converter that is controlled by an upstream controller. In a distributed architecture, control hardware and / or software are also distributed among the controllers, where an equal but modularly configured control scheme can be implemented in each controller, or various cooperative modular control schemes can be implemented in the controllers respective.

Alternatively, the control system can be subdivided into separate local, regional and / or global control subsystems although communicatively linked. Such an architecture can allow a given process or a series of interrelated processes to take place and be controlled locally with minimal interaction with other local control subsystems. A global master control system can then communicate with each of the respective local control subsystems to direct the necessary adjustments to the local processes for a global result. The control system of the present invention may use any of the above architectures, or any other architecture commonly known in the art, which is considered to be within the general scope and nature of the present disclosure. For example, the processes controlled and implemented within the context of the present invention can be controlled in a dedicated local environment, with optional external communication to any central and / or remote control system used for related processes upstream or downstream, when applicable Alternatively, the control system may comprise a sub-component of a regional and / or global control system designed to cooperatively control a regional and / or global process.

For example, a modular control system can be designed in such a way that the control modules interactively control various sub-components of a system, while providing for intermodular communications as necessary for regional and / or global control. The control system generally comprises one or more central processors, in networks and / or distributed, one or more inputs to receive the currently registered characteristics of the various sensor elements, and one or more outputs to communicate new or updated control parameters to the various response elements. The one or more computing platforms of the control system may also comprise one or more local and / or remote computer readable media (eg ROM, RAM, removable media, local and / or network access medium, etc.) for store in them various predetermined and / or adjusted control parameters, operating ranges of the set or preferred process and system characteristics, monitoring of the system and control software, operational data, and the like. Optionally, the computing platforms may also have access, either directly or by means of various data storage devices, to process simulation data and / or means for model and optimization of system parameters. Also, the platforms of computation can be equipped with one or more optional user graphics interfaces and input peripherals to provide management access to the control system (system updates, maintenance, modification, adaptation to new modules and / or system equipment, etc.), as well as various optional output peripherals to communicate data and information with external sources (eg modem, network connection, printer, etc.). The processing system and any of the sub-processing systems may exclusively comprise hardware or any combination of hardware and software. Any of the sub-processing systems may comprise any combination of one or more proportional (P), integral (I) or differential (D) controllers, for example, a P controller, a I controller, a PI controller, a PD controller , a PID controller etc. It will be apparent to a person skilled in the art that the ideal choice of controller combinations P, I, and D depends on the dynamics and delay time of the reaction process part of the gasification system and the range of operating conditions. which intends to control the combination, and the dynamics and delay time of the combination controller. It will be apparent to a person skilled in the art that these combinations can be implemented in an analogous manner wired which can continuously monitor, by means of sensor elements, the value of a characteristic and compare it with a specified value to influence a respective control element to make a suitable adjustment, by means of response elements, to reduce the difference between the observed value and the specified one. It will also be apparent to a person skilled in the art that combinations can be implemented in a mixed digital hardware and software environment. The relevant effects of additional discretionary sampling, data acquisition, and digital processing are well known to a person skilled in the art. The combination control P, I, D can be implemented in advance and feedback control schemes. In a corrective or feedback control, the value of a control parameter or control variable, monitored by means of a specific sensor element, is compared to a specific value or range. A control signal is determined based on the deviation between the two values and provided to a control element in order to reduce the deviation. It will be appreciated that a control system with conventional feedback or feedback can be further adapted to comprise a adapted and / or predictive component, wherein the response to a given condition can be designed according to modeled reactions and / or previously observed to provide a reactive response to a recorded characteristic while limiting potential excessive deviations in the compensatory action. For example, the acquired and / or historical data provided for a given system configuration can be used cooperatively to adjust a response to a characteristic of a system and / or process that is recorded to be within a given range from a value optimum for which previous responses have been monitored and adjusted to provide a desired result. Such adaptive and / or predictive control schemes are well known in the art, and as such, are not considered to depart from the scope and general nature of the present disclosure.

Control elements Sensing elements contemplated within the current context, as defined and described above, are provided to monitor one or more parameters, including, but not limited to, gas flow temperature and flow rate, gas pressure, height of the load pile in the gasifier, gas composition and calorific value, in specific locations throughout the system. The response elements contemplated within the Current context, as defined and described above, may include, but is not limited to, various control elements operatively coupled to devices relative to the process configured to affect a given process by adjusting a given control parameter related thereto. For example, process devices operable within the current context by means of one or more response elements, may include, but are not limited to, air and product gas blowers, feed charge inlets, pressure and temperature regulators, units of lateral transfer and plasma heat sources. In this way, examples of operating conditions which can be adjusted by the response elements of the control subsystem include one or more of the air flow rate exchanged (ie, the speed of the air blower in the process). , the feed charge input ratio, the feed charge input speed (for example, MSW up to high carbon feed load), the system pressure, the movement of the lateral transfer units, the input speed of process additives such as water vapor, and the power for plasma heat sources. In one embodiment of the invention, the control subsystem comprises temperature sensing elements for monitoring the temperature at sites located along the system. The temperature sensing elements for monitoring the temperature may be temperature transmitters such as thermocouples or optical thermometers installed in locations in the system as required. Figure 9 details an introduction of various means to monitor and control the temperature within the system, indicating the location at which the temperature transmitters and flow regulators are installed throughout the system. For example, 5982 temperature transmitters are located to monitor the product gas temperature at the gas outlet of the gas heat exchanger product to air 5926. The 5981 temperature transmitters are also located to monitor the heated exchange air temperature 5015 in the exchange air outlet 5917 from the gas heat exchanger to air 5109. The temperature transmitters can also be located along the converter in order to monitor the processing temperatures during the gasification and reformulation processes. The monitoring of the temperature, for example, in the region of the converter in which the gasification process takes place, assuring the optimum conversion efficiency by maintaining the power load pile as high at a temperature as possible in a manner that is possible, without reaching temperatures that melt or agglomerate the power load. The temperature control within the stack is made by adjusting the heated exchange air flow to the interior of a given region of the 2009 gasifier through adjustments for control valves 5994A, 5994B and 5994C, in order to stabilize the temperatures as required for the different stages of the gasification process. The temperatures in the different stages are measured by temperature transmitters 5984A, 5984B and 5984C, respectively. Controlling the temperature in the different stages of the gasification process can also be done by controlled movement of the feed through the gasifier by the lateral transfer units. The temperatures in the reformulation region 3009 of the converter are monitored by the temperature transmitter 5983. The power for the plasma torches 2980 can be adjusted as required in order to stabilize the temperatures in the reformulation region 3009 in order to maintain a optimum temperature to completely reformulate the exit gas, volatiles, tars and soot into a defined gas product. The temperature transmitter 5981 installed in the exchange air outlet 5917 to measure the temperature of the heated exchange air ensuring that the recycling process is carried out under conditions that ensure that the air is heated to a temperature appropriate for use in the gasification process. For example, if the optimum exchange air temperature for use in a gasifier is around 600 ° C, a temperature transmitter installed in the air outlet stream will be used to ensure the exchange air temperature does not exceed, by example, 625 ° C. In order to avoid providing too much heated exchange air (or exchange air that is too hot) for the gasification process, which can result in overheating of the feed load, a 5990 control valve opens to vent the excess air exchange in the atmosphere. In this way, the means for controlling the control valve 5990 to vent the exchange air to the atmosphere are also optionally provided. For example, in some cases it is necessary to heat more air than required for the process due to equipment considerations (for example, when starting a closed procedure). In such cases, the exchange air can be ventilated as required. According to one embodiment of the invention, the control strategy establishes a fixed set point for the optimum heated exchange air outlet temperature, for example, around 600 ° C. In such a mode, even when the exchange air flow through the exchange of gas heat to air is reduced, the outlet gas temperature of the heat exchange of 5 gas to air will subtract the same. The reduced air flow through the heat exchange of gas heat to air will therefore result in an increased product gas temperature from the gas-to-air heat exchange, and enter the next stage of the process, for example, a 10 heat recovery steam generator. When the flow of air through the system is reduced, however, the flow of product gas will also consequently reduce, the intake gas temperature increased product for the steam generator of water. 15 heat recovery will only be high momentarily. : For example, if the air flow is reduced to 50%, the maximum inlet temperature of the product gas that the steam generator will have to be momentarily appraised is approximately 800 ° C, which is within the limits : 20 design temperature. The monitoring of the product gas temperature at the gas-to-air heat exchange input can also ensure that the temperature of the product gas as it enters a respective heat exchange does not exceed the Ideal operating temperature of such device. For example, if the design temperature for gas-to-air heat exchange is 1050 ° C, the temperature data obtained from a temperature transmitter in the inlet gas stream for heat exchange can be used to control both the flow rates of exchange air through the system as plasma heat power in order to maintain the optimum product gas temperature. In addition, measuring the temperature of the product gas at the gas outlet resulting from the gas-to-air heat exchange can be useful to ensure that the optimum amount of sensible heat has been recovered from the product gas in the heat recovery stage. If the temperature of the gas leaving the converter exceeds a predetermined limit, this may be an indication that the pipes start to clog, at which time the system must be turned off for maintenance. The heat exchangers are therefore provided, as required, with ports for convenient inspection and maintenance. In one embodiment of the invention, the control subsystem comprises sensor elements for monitoring pressure and gas flow rate along the gasification system. These pressure sensing elements may include pressure sensors such as transducers of pressure, pressure transmitters or pressure taps located in the system, for example, in a vertical wall of the gasifier, or in association with elements downstream of the gasification system such as a gas storage tank. Data relating to pressure and gas flow in the system is used by the control subsystem to determine if adjustments for parameters such as torch power or the addition ratio of solid waste material are required. In one embodiment of the invention, the control subsystem comprises response elements for adjusting the pressure within the system, thereby maintaining a desired pressure in the system within certain defined tolerances. Any pressure variations caused, for example, when using the product gas torch velocity or exchange air input ratio, are corrected by making adjustments to certain operational parameters as determined by the control subsystem. Figure 10 describes an introduction of various means for monitoring and controlling the pressure and flow of the product gas throughout the system. The 7095 pressure transmitters in a downstream storage tank 7010 send a signal to the exchange air flow control valves in the 1010 converter, for this, for example, a decrease in the pressure of the gas storage tank sends a signal to increase the exchange air flow in the gasifier 2010, and vice versa. The exchange air flow for the 2010 gasifier is controlled using control valves 5994A, 5994B and 5994C. An increased amount of exchange air 5015 administered to the gasifier 2010 results in an increased ratio in which the feed load is gasified, thereby producing in an increased product gas flow 5020 (and an increase in system pressure). Any change in demand for the exchange air 5015 in the 2010 gasifier affects the discharge pressure of process air blowers as measured by the pressure transmitter 5095, which then adjusts the speed in the variable frequency pulse (VFD) ) in the process air blower 5012. The air blower speed of process 5012 is increased when low pressure is detected in storage tank 7010, and the speed is decreased when high pressure is detected in the storage tank . When an increased amount of gas is produced, the control subsystem can also automatically adjust the speed in a VDF gas blower to alleviate this pressure increase, by administering more gas to the storage tank than results in an increase in storage tank pressure. In response to data acquired by pressure sensors located throughout the system, the speed of the downstream induction blower is adjusted according to whether the pressure in the system increases (thus the fan will decrease in speed) or decreases ( therefore the fan will decrease in speed). In one modality, the data is related to the pressure points throughout the system are obtained on a continuous basis, which allows the control subsystem to make frequent adjustments to the fan speed to maintain system pressure within from a predetermined set point. In one embodiment, the system is maintained under light negative pressure relative to atmospheric pressure to prevent gases from being expelled into the environment. In one embodiment, the internal pressure is adjusted using an induction blower located downstream of the gasifier that operates by entraining the gas product from the gasifier. The induction blower thus used maintains the system at atmospheric or negative pressure. In one embodiment, a control valve is provided in a coated gas outlet to increase or restrict the gas flow that is removed by the downstream gas blower. In systems in which the positive pressure is maintained, the blower is operated such that the elimination ratio of the product gas is reduced, or even completely extinguished, so that the gases are forced to "propel" their trajectory through the system that results in a higher (positive) pressure. »Fluctuations in the gas flow can occur as a result of inhomogeneous conditions in the gasification process (eg malfunction in the torch, blockages in the gas lines, or interruptions in the feeding load input). If the fluctuations persist in the gas flow, the system can be turned off until the problem is solved. Since the addition of high carbon feed charges, air process additives and / or water vapor during the gasification process affects the conversion chemistry, it is desirable to monitor the composition of the product gas. In one embodiment of the invention, the control subsystem comprises sensor elements for monitoring the composition of the gas product. Monitoring of the product gas composition can be performed, for example, by means of a gas analyzer. A gas analyzer can determine, for example, the content of hydrogen, carbon monoxide and / or carbon dioxide of the product gas. A method that can be used to determine the chemical composition of the product gas is through gas chromatography (GC) analysis. The sample points for these analyzes can be located throughout the system. In one embodiment, the gas composition is measured using an Infrared Fourier Transform Analyzer (FTIR), which measures the infrared spectrum of the gas. Although there are high temperature gas analysis devices, the composition is generally measured after the product gas has cooled and then undergoes a conditioning step to remove particulate matter and other contaminants. The composition of the product gas can be controlled by controlling the composition of the feed charge (for example, the ratio of MS to HCF) that is gasified, as well as the process additives of the amount of air and / or water vapor added. to the gasification and reformulation reactions. In this way, the control subsystem provides a means to control the ratio of the MSW to HCF, the ratio of the addition of the feed charge current, as well as the process additives of the amount of air and / or water vapor they are added to the converter. In one embodiment of the invention, the subsystem of control comprises means for adjug the ratio and / or quantities of the air inlets to the interior of the gasifier and / or the reformulator. In one embodiment of the invention, the control subsystem comprises means for adjug the ratio and / or quantities of the water vapor inputs to the interior of the reformulator. In one embodiment of the invention, the control subsystem comprises means for adjug the addition ratio of the high carbon feed charge (HCF) inputs to the gasifier, in response to the process demands for higher or lower input of carbon to provide the desired gas composition. In one embodiment of the invention, the control subsystem comprises means for adjug the addition ratio of MSW for the gasifier. The MSW and optionally the HCF inputs are added to the gasifier using a number of possible input means that are selected and adapted as required for the shape of the aggregate material. The materials can be added in a continuous manner, for example, by the use of screws or drill mechanism.

Alternatively, the materials may be added in a discontinuous manner, for example, by using a plunger driver to add the material in portions as required. In one modality, the input ratio of the load The feed rate is controlled by adjusting a speed of the feed screw conveyor by means of a variable frequency pulse motor drive (VDFs). The input ratio will be adjusted as required in accordance with the heating capacity of the heated exchange air inlets. The system may further comprise means for monitoring and controlling the height of the stack (or level) in order to maintain stable processing conditions within the converter. This provides the ability to keep the stack height stable inside the converter. The height of the stack that prevents fluidization of the exchange air injection material that can occur at low level is controlled, while also preventing the distribution of poor temperature through the stack that results from restricted air flow that must occur at a high level. A stable stack height is maintained which also ensures the consistent residence time of the converter. A series of level switches in the gasifier measure the pile depth. In one embodiment, the level switches are microwave devices with one emitter on one side of the gasifier and one receiver on the other side, which detects either the presence or absence of solid material at such point within the converter. In one embodiment of the invention, there are provided lateral transfer units to move the material that is gasified through the different regions of the gasifier. The quantity and location of the feed charge in the gasifier is a function of feed and movement ratio of the lateral transfer units, as well as the quantities of heated exchange air inlets. Thus, in such an embodiment, the control subsystem comprises means for controlling the movement of the material through the different regions of the gasifier as required. In one embodiment, the lateral transfer units are pistons, wherein the feed load is transported through the different regions of the gasifier at a ratio determined by the length and frequency of the blow. For example, the control subsystem may employ limit switches or other control displacement means such as computer-controlled variable speed motor drive to control the length, speed and / or frequency of the plunger stroke so that the amount of material moved with each stroke can be controlled. In one embodiment, the lateral transfer units comprise one or more screw conveyors, wherein the transfer ratio of the material through the gasifier is controlled by adjusting the speed of the conveyor. conveyor by means of the variable frequency pulse of the impulse motor. In one embodiment of the invention, the control subsystem comprises means for adjusting the power, and optionally the position, of the plasma heat source. For example, when the temperature of the gas product at the gas outlet of the converter is too high, the control subsystem order a drop in the power rating of the plasma heat source.

Use of the gasification system / The process The system according to the present invention gasifies a feedstock, using a process for the gasification of the feedstock which generally comprises the step of passing the feedstock into the interior of a converter where it is subjected to the heating effect of heated exchange air. During heating by the exchange air, the feedstock is dried and the volatile components in the dry feedstock are volatilized. In one embodiment of the invention, the heated exchange air further promotes the complete conversion of the resulting carbonaceous waste to its gaseous constituents, starting from an ash by-product. The combined products of the drying, volatilization and combustion stages provide an exit gas, which is further subjected to heat from a plasma heat source to convert the exit gas to a hot gas product comprising carbon monoxide, carbon dioxide, hydrogen, water vapor (and nitrogen due to the use of air in the gasification process). The water vapor and / or air process additives can optionally be added to the gasification stage and / or the outlet gas conversion stage. In one embodiment of the invention, the process further comprises the step of subjecting the ash from the by-product to heating by means of a second plasma heat source to form a slag product. The process of the present invention further comprises the steps of passing the hot gas product through a heat exchanger, transferring the heat from the hot product gas to air to produce a heated exchange air and a cooled product gas, and using the heated exchange air in the gasification of the carbonaceous feed charge. The process of the present invention further comprises the steps of passing the cooled gas product into a second heat exchanger, which transfers the heat of the first cooled gas to the water to produce additional water vapor and chilled gas. The process of the present invention maximizes the pure conversion efficiency by compensating the amount of electricity consumed to create the heat which drives the gasification process, to drive the rotating machine, and for the power of the plasma heat sources. For applications that aim to generate electricity, efficiency is measured by comparing the energy consumed by the general gasification process with the amount of energy generated using the product gas (for example, to power gas turbines or cell technologies). of fuel), and through the recovery of sensible heat to generate steam to enhance the steam turbines of water. The gasification process may further comprise a feedback control stage for adjusting one or more of the input ratio of the feed charge, the flow rate of the exchange air, the product gas flow rate, the input ratio of the water vapor process additive and the amount of power supplied to the plasma heat sources based on changes in the flow / pressure of flow, temperature and / or composition of the product gas. The feedback control stage in this manner allows the flow rate, temperature and / or composition of the synthesis gas to be maintained within acceptable ranges. In an embodiment of the present invention, the The process further comprises the step of preheating the carbonaceous feed charge before being added to the converter. In one embodiment, the gasification process in accordance with the present invention employs the use of exchange air to heat the gasifier to an appropriate temperature to gasify the feed charges. In another embodiment, which is typically used in the start phase of the system, the air is fed into the system, so it can be heated using plasma heat, or heat recovery from other stages in the gasification processes, to provide a hot start gas which then enters the gas-to-air heat exchanger to generate heated exchange air. The exchange air is transferred to the exchange air inlets to heat the gasifier, such that the entire process can be run without the use of fossil fuels. Figures 11A through 111 describe various options for heat recycling according to the present invention. Figure 11A is a block flow diagram describing an embodiment of the invention, wherein the hot product gas 5020A is produced by gasifying the carbonaceous feed charge in a converter 1000A. The hot product gas 5020A is passed through a heat exchanger 5100A, where the heat is transferred from the hot product gas 5020A to the air blower 5010A through the heat exchanger by an air blower 5012A to produce the heated exchange air 5015A and a cooled product gas 5025A. The heated exchange air 5015A is then passed back into the converter 1000A to drive the gasification process. The cooled product gas 5025A is then further cooled by a dry-off stage 6111A before passing through a gas conditioning system 6000A. The product gas, after cooling and cleaning, is then burned in a 5060A gas engine, and hot combustion gases 5061A are sent to the atmosphere. Figure 11B is a block flow diagram describing an embodiment of the invention, wherein a hot product gas 5020B is produced by gasifying the carbonaceous feed charge in a converter 1000B. The hot product gas is passed through a heat exchanger 5100B, where the heat is transferred from the hot product gas 5020B to the air blower 5010B through the heat exchanger through an air blower 5012B to produce heated exchange air 5015B and a product gas cooled 5023B. The heated exchange air 5015B is then passed back into the converter 1000B to drive the gasification process. The heat Additional is recovered from the cooled product gas 5023B by passing the product gas through a generated heat recovery water vapor 5300B before passing through a gas conditioning system 6000B. The additional heat is transferred to water 5030B to produce steam 5035B. The product gas, after cooling and cleaning, is then burned in a 5060B gas engine, and hot combustion gases 5061B are sent to the atmosphere. Fig. 11C is a block flow diagram describing the embodiment of Fig. 11B, wherein the hot combustion gases 5061B of the gas engines are passed through a second heat recovery steam generator 5300C, where the heat of the hot combustion gases is transferred to 5030C water to generate 5030C water vapor. Fig. 11D is a block flow diagram depicting the embodiment of Fig. 11B, wherein water vapor 5035B generated in the 5300B heat recovery steam generator is used to power a 5065D steam turbine. to generate electricity. Figure 11E is a block flow diagram describing the embodiment of Figure 11C, wherein the water vapor (5035B and 5035C) generated in the heat recovery steam generators (5300B and 5300C) is combines and uses to power a 5065E steam turbine to generate electricity. Fig. 11F is a block flow diagram describing the embodiment of Fig. 11B, wherein the heated exchange air 5015B is also passed into a feed charge conditioner 5067F to pre-dry the feed charge 5088F before of feeding into the interior of the 1000B converter for gasification. Figure 11G is a block flow diagram describing the embodiment of Figure 11B, wherein the water vapor 5035B generated in the heat recovery steam generator 5300B is used to indirectly heat a feed charge conditioner 5067G, therefore pre-dry the feed charge 5088G before feeding into the converter 1000B for gasification. Fig. 11H is a block flow diagram describing an embodiment of the invention, wherein the hot product gas 5020H is produced by gasifying the carbonaceous feedstock in a 1000H converter. The hot product gas 5020H is passed through a 5100H heat exchanger, where the heat is transferred from the hot product gas 5020H to the air blower through the heat exchanger through a 5012H air blower to produce heated exchange air 5015H and a product gas cooled 5025H. The heated exchange air 5015H is then passed back into the converter 1000H to drive the gasification process. The cooled product gas is then passed through a gas conditioning system. The product gas, after cooling and cleaning, is then burned in a 5060H gas engine, and hot combustion gases 5061H are sent to the atmosphere. This embodiment includes a solid waste conditioning step, where the hot gases produced in the solid waste conditioner 4020H are also passed through a heat exchanger 5105H, where the heat from the hot gases is transferred to air 5110H which it is blown through the heat exchanger 5105H to produce a second heated air product 5115H. The second heated air product 5115H is then used to indirectly heat a 5067H feed charge conditioner, therefore the feed charge 5088H is pre-dried before being fed into the converter 1000H for gasification. Figure 111 is a block flow diagram describing an embodiment of the invention, wherein the hot product gas 50201 is produced by gasifying the carbonaceous feed charge in a converter 10001. The gas Hot product 50201 is passed through a 51001 heat exchanger, where the heat is transferred from the hot product gas 50201 to the air blower through the heat exchanger by an air blower 50121 to produce heated exchange air 50151 and a cooled product gas 50251. The heated exchange air 50151 then becomes to pass inside the converter 10001 to drive the gasification process. The cooled product gas 50251 is then passed through a gas conditioning system 60001, and into a system for storing and homogenizing the gas product 70001. A portion of the product gas 51251 is then burned in a gas engine 50601 , and the hot combustion gases 50611 are sent to the atmosphere, while another portion of the product gas 52251 is burned in a gas burner 50671 to provide heat to preheat the converter 10051 of another gasification system. The invention will now be described with reference to a specific example. It will be understood that the following example is intended to describe an embodiment of the invention and is not intended to limit the invention in any way.

EXAMPLE In general, the system of the present invention is used for the air exchange of power to the interior of a converter where the feed load is subjected to sufficient heat to allow the gasification reaction to take place. In the exemplary embodiments described in Figure 12 and 13, gasifiers 2100 and 2200 each have sloping floors that have three floor levels, or stages. Optionally, each level of floor tilts between about 5 and about 10 degrees. In a stepped stage gasifier, the individual stages (floor levels) provide appropriate conditions for the respective drying, volatilization and conversion steps of the respective ash-to-ash residue of the gasification process, thereby allowing for the optimization of the gasification process. In each of these exemplary gasifiers, the feedstock is fed in the first stage, where the conditions are provided such that the main process in the present is the drying, with some volatilization and conversion of the ash-to-ash residue . The normal temperature range for this stage (as measured at the bottom of the material stack) is between 300 and 900 ° C. The dry feed charge is then transferred to the second stage, where the conditions are provided such that the main process in the present one is that of volatilization of the dry feed charge to form the carbonaceous waste, with a small degree (the remainder) from the dry operation as well as some conversion of carbonaceous-to-ash residue. The normal temperature range for this stage is between 400 and 950 ° C. The carbonaceous residue is then transferred to the third stage, where the conditions are provided such that the main process is that of conversion of the carbonaceous-to-ash residue with a minor amount (the remaining) of volatilization. The normal temperature range is between 600 and 1000 ° C. Movement during the stages is facilitated by lateral transfer units with each stage optionally serving by an independently controlled lateral transfer unit. In the mode of the gasifier described in Figure 12, the gasifier 2100 comprises a horizontally oriented refractory lined gassing chamber 2102 having a feed charge inlet 2104, gas outlet 2106 and a solid waste outlet 2108. The gasification chamber 2102 has a sloping floor with a plurality of floor levels 2112, 2114 and 2116. Each floor level has a series of exchange air inlets 2126 located on the side walls near the floor level to allow the addition of air from the floor. exchange. The exchange air inlet is regulated to promote the gasification of the reactive material.

In the mode of the gasifier described in Figure 13, the gasifier 2200 comprises a horizontally oriented refractory lined gasification chamber 2202 having a feed charge inlet 2204, gas outlet 2206 and a solid waste outlet 2208. The gasification chamber 2202 has a sloping floor with a plurality of floor levels 2212, 2214 and 2216. Each level or stage has a perforated floor through which heated air can be introduced. The air supply for each level or stage is controlled independently. The independent supply and distribution of air through the perforated floor 2270 is done by a separate air box 2272, 2274, and 2276 which forms the floor in each stage. A representative air box is illustrated in Figure 14, which clearly shows the perforated upper plate 2302 of the air box, as well as a connecting flange 2280 for connection to the exchange air pipe system. The exhaust gases formed in the gasifier were then further treated in a reformulation chamber with a plasma heat source and optionally with steam and additional heated exchange air. These devices are optionally added in the reformulation stage to ensure the formation of a product gas which has a defined composition. The temperature during the reformulation step is maintained in a range that is sufficiently high to maintain the reactions at an appropriate level to ensure complete conversion for the defined gas product, while minimizing the production of contamination. In the exemplary embodiment, the temperature range of the reformulation step is from about 900 ° C to about 1300 ° C. If, after the reformulation stage, the temperature of the product gas is too high, the water vapor is optionally added to reduce the outlet temperature of the product gas. The product gas leaves the plasma reformulation zone at a temperature of about 900 ° C to about 1100 ° C. In exemplary mode, the product gas outlet temperature is around 1000 ° C +/- 100 ° C. The flow rate of the hot product gas is around 6000 Nm3 / hr to about 9500 Nm3 / hr, typically around 7950 Nm3 / hr. The hot product gas then passes into a gas-to-air heat exchanger. In the current example, air enters the gas-to-air heat exchanger at room temperature, that is, from about -30 to about 40 ° C. Air circulates through the system using air blowers, which enters the heat exchanger of gas-to-air at a ratio of about 1000 Nm3 / hr to 5150 Nm3 / hr, typically at a ratio of about 4300 Nm3 / hr. In the current example, the air is heated in the heat exchanger to produce exchange air having a temperature of about 500 ° C to about 625 ° C. In the exemplary embodiment, the exchange air temperature is around 600 ° C. The hot product gas, in turn, is cooled to a temperature of about 500 ° C to about 800 ° C.

In the exemplary embodiment, the temperature of the product gas is about 740 ° C. The heated exchange air is passed into the gasifier through the exchange air inlets to gasify the feed charge, as discussed above. The gas-to-air heat exchanger of the exemplary embodiment is a protected tube-type heat exchanger designed specifically for the high level of particulate loading in the product gas, where the product gas flows on the sides of the tube, and the counter-current air flows on the side of the enclosure. In the exemplary embodiment, the cooled product gas is further cooled using a dry-off step to remove excess heat from the product gas, thereby providing a cooled product gas as required for the subsequent filtration and conditioning stages. The cooled product gas is then further passed through a gas conditioning stage to remove acid gases, heavy metals, particulate matter and other contaminants. The waste byproducts of the gasification process are further conditioned in a waste conditioning chamber by fusing with a dedicated plasma heat source. The products of the waste conditioning stage are an inert slag material and a hot gas. Although the invention has been described with reference to certain specific embodiments, various modifications thereof will be apparent to those skilled in the art without departing from the spirit and scope of the invention as summarized in the claims appended hereto. The description of all patents, publications, including published patent applications, and entries of databases referenced in this specification are specifically incorporated for reference in their entirety to the same extent as if each individual patent, publication, and entry of databases of Data was specifically and individually indicated to be incorporated for reference.

Claims (34)

1. A system that recycles heat recovered from a hot gas comprising a reformulated plasma gas to a carbonaceous feed charge gasifier, the system comprises: means for transferring the hot gas comprising reformulated plasma gas to a gas-to-heat exchanger -fluid, where the heat of the hot gas comprising a reformulated gas of plasma is transferred to a fluid to produce a hot fluid and refrigerated gas; means for transferring the hot fluid to the gasifier; and a control system comprising sensor elements for monitoring the operating parameters of the system, and response elements for adjusting the operating conditions within the system to optimize the gasification process; where the response elements are adjusted to the operating conditions within the system according to the data obtained from the sensor elements, thus optimizing the efficiency of the gasification process by minimizing the energy consumption of the process, while at the same time that maximizes the production of energy.

2. System according to claim 1, wherein the fluid is air, water, oil or a gas.

3. System according to the fluid claim is air and the gas heat exchanger a gas-to-air heat exchanger.

4. System according to the fluid claim is water and the gas heat exchanger a heat recovery steam generator.

5. Process for improving the efficiency of a carbonaceous feed charge gasification process by recycling the sensible heat of a hot gas produced by the gasification and plasma reformulation processes within the gasification process using a gas-to-fluid heat exchanger comprising a gas inlet produced hot in communication with a chilled produced gas outlet, and a fluid inlet cooled in communication with a hot fluid outlet, the process comprises the steps of: passing hot gas comprising a reformulated plasma gas through of the input of hot produced gas inside the exchanger of gas-to-fluid heat; passing the cooled fluid through the cooled fluid inlet into the gas-to-fluid heat exchanger so that the heat is transferred from the hot gas comprising a reformulated plasma gas to the fluid cooled by the gas heat exchanger. fluid to produce a cooled produced gas which exits the heat exchanger through the output of cooled produced gas, and a hot fluid which leaves the heat exchanger through the hot fluid outlet; and using the hot fluid to provide heat to the carbonaceous feed charge gasification process.

6. Process according to claim 5, wherein the fluid is air and the gas-to-fluid heat exchanger is a gas-to-air heat exchanger.

7. Heat recycling system configured for operative association with a gasification system comprising a gasifier, a plasma gas reformer and optionally a solid waste conditioning chamber to recover heat from the hot gas generated by the gasification system and supply the heat to one or More than heating applications, the heat recycling system comprises: a) one or more gas-to-fluid heat exchangers configured to transfer heat from the hot gas to a fluid to produce a hot fluid; b) one or more hot gas ducts configured to provide fluid communication between one or more sources of hot gas and the one or more gas-to-fluid heat exchangers; and c) one or more fluid conduits configured to provide fluid communication between the one or more gas-to-fluid heat exchangers and the one or more heating applications, where the heat recycling system is optionally operatively associated with a system control comprising: A. one or more sensor elements configured to mark one or more characteristics of a process, a process device, a process input and / or a process output; B. one or more response elements configured to affect one or more characteristics of one or more processes within the heat recycling system; and C. one or more computing platforms operatively associated with one or more of the sensor elements and one or more of the response elements, the one or more computing platforms configured to receive input signals from at least one sensor element and for supplying control signals to at least one response element to either maintain or adjust a characteristic of the process within the heat recycling system; the control system configured to use direct feed control or feedback control or prediction control or adaptation control or a combination thereof, where one or more of the gas-inflow heat exchangers, hot gas ducts and / or fluid conduits are optionally operatively associated with one or more sensing and / or response elements, and wherein the hot gas comprises a reformulated plasma gas generated by the gasifier and plasma gas reformer and / or a waste gas generated by the chamber of solid waste conditioning.

8. The system of claim 7, wherein the one or more heating applications are one or more of the gasifier, the gas reformer, a gas conditioning system, a gas cooling system, the solid waste conditioning chamber, a system of gas homogenization, a conduit that connects these systems, a steam generator and / or a motor.

9. The system of claim 7, wherein the fluid in at least one of the gas-to-fluid heat exchangers is air, water, oil or a gas.

10. The system of claim 7, wherein the fluid in at least one of the gas-to-fluid heat exchangers is air, and the gas-to-fluid heat exchanger is a gas-to-air heat exchanger configured to transfer heat. from the hot gas to the air to produce an exchange of hot air and a cooled gas.

11. The system of claim 7, wherein the fluid in at least one of the gas-to-fluid heat exchangers is water, and the gas-to-fluid heat exchanger is a heat recovery steam generator.

12. The system of claim 11, wherein the one or more heat recovery steam generators are operatively associated with a steam turbine so that the steam generated drives the turbine.

13. The system of claim 11, wherein the one or more steam generators are operatively associated with the gasifier to supply steam thereto as an additive to the process for the gasification process.

14. The system of claim 10, wherein the gas-to-air heat exchanger is configured to transfer the hot air exchange through one of the fluid conduits to the gasifier to supply at least a portion of the heat required to conduct the gasification process within the gasifier. of the gasifier.

15. The system of claim 10, wherein the gas-to-air heat exchanger is configured to transfer the hot air exchange through one of the fluid conduits to supply at least a portion of the heat to preheat the feed charge. carbonaceous and / or remove moisture from the carbonaceous feed charge for the gasifier.

16. The system of claim 10, wherein the system is configured to transfer heat from the hot air to oil exchange to supply a hot oil to heat a dryer / feed charge preheater.

17. The system of claim 10, wherein the system is configured to transfer the hot air exchange to supply heat to a dryer / feed charge preheater.

18. The system of claim 10, wherein the system is configured to transfer heat from the hot air exchange to the water to produce steam.

19. System of claim 18, wherein the steam is for heating a dryer / feed charge preheater.

20. The system of claim 10, comprising in addition one or more heat recovery steam generators to generate steam using waste heat from the cooled gas.

21. The system of claim 20, wherein the one or more heat recovery steam generators are operatively associated with a steam turbine so that the steam generated drives the turbine.

22. The system of claim 20, wherein the one or more steam generators are operatively associated with the gasifier to supply steam thereto as a process additive for the gasification process.

23. The system of claim 7, wherein the gas-to-fluid heat exchanger is a tub and a tubular heat exchanger.

24. The system of claim 7, wherein the gas-to-fluid heat exchanger is a plate type heat exchanger.

25. System of claim 7, wherein the Gas-to-fluid heat exchanger is configured to tolerate a high level of particle loading, where the particle size ranges from 0.5 to 100 microns.

26. The system of claim 7, wherein the heat recycling system is configured to tolerate gas velocities between 3000 to 5000 m / min.

27. The system of claim 7, wherein the heat recycling system comprises one or more individual temperature transmitters optionally operatively associated with one or more sensing and / or response elements.

28. The system of claim 7, wherein one or more of the hot gas and / or fluid conduits are operatively associated with a flow management system comprising one or more of a flow regulating device, flow meter and / or fan to control the flow rate of the hot gas or hot fluid, where the flow management system is optionally operatively associated with one or more sensor and / or response elements.

29. System of claim 7, wherein the system The heat recycle comprises one or more hot fluid flow control valves for controlling the flow rate of the hot fluid to the gasifier, where at least one of the hot fluid flow control valves is optionally operatively associated with one or more sensor elements. and / or response.

30. System of claim 7, wherein the heat recycling system is integrated into a gasification installation and is configured to supply heat to one or more locations within the facility.

31. The system of claim 7, wherein the heat recycling system is integrated into a gasification installation and is configured to supply heat to one or more locations for transfer to a site outside the facility.

32. The system of claim 7, wherein the system is operatively associated with a control system comprising: A. one or more sensor elements configured to mark one or more characteristics of a process, a process device, a process input and / or a process output; B. one or more response elements configured to affect one or more characteristics of one or more processes within the heat recycling system; Y C. one or more computing platforms operatively associated with one or more of the sensor elements and one or more of the response elements, the one or more computing platforms configured to receive input signals from at least one sensor element and to supply control signals to at least one response element to either maintain or adjust a process characteristic within the heat recycling system; the control system configured to use direct feed control or feedback control or prediction control or adaptation control or a combination thereof.

33. Process to recover heat from a hot gas generated by a gasification system comprising a gasifier, a plasma gas reformer and optionally a waste conditioning chamber solids, the process comprising the steps of: a) passing the hot gas from one or more sources of hot gas into the gasification system through a gas-to-fluid heat exchanger to supply a hot fluid, where the gas hot comprises a reformulated plasma gas generated by the gasifier and plasma gas reformer and / or a waste gas generated by the solid waste conditioning chamber, and b) transfer the hot fluid to one or more heating applications.

34. Process of claim 33, wherein the one or more heating applications are one or more of: the gasifier, the gas reformer, a gas conditioning system, a gas cooling system, the solid waste conditioning chamber, a gas homogenization system, a conduit connecting these systems, a steam generator and / or a motor.