NO309930B1 - Use of a fluidized bed for the conversion of carbonaceous material into product gas, energy recovery and chemical content in black liquor, and for steam reforming of heavy, liquid hydrocarbons - Google Patents

Description

This invention relates to indirectly heated thermo-kinetic reactors and processes or methods for performing thermochemical reactions, including such as steam reforming of heavy oils, alkali recovery and energy recovery.

Methods for carrying out thermochemical reactions include a wide spectrum of reactions where raw materials are directly or indirectly heated to effect desirable endothermic reactions.

In the case of directly heated reactors, exothermic reactions effected or taking place in situ will provide the heat of reaction for the desired endothermic processes. Examples of such directly heated systems include partial oxidation and autothermal carburetors. Although these systems can be used to gasify e.g. carbonaceous material, including biomass, the product gas is of low quality due to the presence of diluents, i.e. the products of the exothermic reactions.

Higher quality products can be produced by the use of indirectly heated reactors. For example, several methods have been used for indirectly heated biomass gasification. One method uses a conventional combustion chamber with combustion tubes immersed in a fluidized bed reactor. Flanigan et al., Proceedings of the 15th Biomass Thermochemical Conversion Contractor's Meeting, Atlanta, Georgia, pp. 14-30 (1983). Another method uses an additional charring combustion chamber of fluidized bed type which heats sand in a separate layer. The hot sand is then used as the heat delivery medium in the primary fluid bed gasifier reactor. Feldman et al., Proceedings of the 15th Biomass Thermochemical Conversion Contractor's Meeting, Atlanta, Georgia, pp. 31-90 (1983).

In the first method, the large size of the combustion chamber and the heat exchange subsystem will result in high costs compared to directly heated reactors. The main disadvantages of indirectly heated reactors with conventional fire tubes have always been the high costs due to the size of the heat exchangers and the high temperature materials necessary for the construction of such heat exchangers. In addition, the large number of tubes required for the heat exchange will be a compromise with the reactor bed or reactor bed fluidization. (Hereinafter, the word "bed" is most often used instead of "layer" in the description.) Thus, low heat emission rates in the combustion chamber and low heat transfer rates in the combustion tubes will limit the reactor's performance and its economic viability.

In the second method, it is difficult to achieve char combustion to replace the wart value of the charred mass without a long transit time and excess air, which requires an even larger combustion chamber (than the carburettor), and which further reduces the efficiency of the system. In addition, the size and complexity of the hot sand recirculation equipment and the cost of the additional fluidized bed carbonization combustor would both represent serious drawbacks.

In another example, previously known steam reforming of heavy, volatile hydrocarbons involves a number of fixed-bed and fluid-bed methods which are subject to serious operational problems.

Most steam reformers for treating heavy liquid hydrocarbons to produce hydrogen-rich gas are autothermal and operate at high temperatures. However, this is a compromise with the quality of the produced gas due to the emission of thinners (products of the combustion in the product gas), especially if the system uses air blowing.

This led to the development of two indirectly heated steam reformers of note, one being the total hydrocarbon reforming (THR) process (Tomita, High Temperature Processing Symphosium, sponsored by KTI Company, Santa Barbara, CA (1979), Tomita et al., European Meeting of Chemical Engineering, 18th Chemical Congress and Exhibition, Frankfurt Germany (1976)), and the other is a catalytic fluidized steam reforming process ((hereafter referred to as "the French process")), bulletin of Secoete de al Grande Paroisse, (1973)) .

In the THR process, hydrogen is produced by the reaction between steam and the heavy liquid hydrocarbons in a tubular reactor with a fixed bed. This process is catalytic and is reported to accept a wide range of feedstocks including naphtha and crude oil without the need for any pretreatment of the feedstocks. The THR process uses a catalyst that works in the presence of sulfur.

The primary catalyst is called T12 and is a silicon-free, calcium aluminate-based catalyst. Since the steam reforming activity of this catalyst is lower than that of conventional nickel catalysts, the required reaction temperature is higher. For a heavy raw material such as Iranian heavy crude oil, the inlet temperatures are thus 1173K and the outlet temperatures as high as 1273K, which causes serious heat transfer and pipe material problems. It should also be noted that it was necessary to develop a complex new feed system to control the heavy fuel vaporization and heavy mixtures with steam to avoid cracking and soot formation in the reformer inlet.

Since the nickel-free T12 catalyst is not sufficiently active to convert the entire amount of hydrocarbons into synthesis gas, the exhaust gas inevitably contains a high level of methane, and this is especially true when you have heavy raw materials. To solve this problem of hydrocarbon breakthrough, a nickel-containing catalyst (T-48) is used at the end of the fixed bed of T-12 calcium aluminate. The T-48 nickel catalyst, located adjacent and upstream of the T-12 catalyst, tolerates sulfur in this process since it is operated at high temperatures, typically 1172°K, and significant amounts of H2 are present. For steam reforming of crude oil, the THR process is more expensive than conventional naphtha steam reforming.

It is obvious to those skilled in the art of steam reforming that the treatment of heavy hydrocarbons entails particular problems due to the presence of aromatic element moieties contained in the heavy hydrocarbons, and which have a particular tendency to form carbonaceous deposits or soot on catalyst substrates. In the THR process, the primary catalyst is arranged in a tubular fixed bed reactor. The deposition of carbonaceous deposits in such tubular fixed bed reactors results in clogging of the catalyst flow volumes. In the fixed-bed design, the process of deposition and clogging is progressive, which leads to extensive pressure drop in the tubular reactor and will require shutdown. Since deposit formation cannot be tolerated in fixed-bed reactors, process conditions must therefore be established so that deposit is avoided or minimized. This generally requires the use of high steam to carbon ratios, which increases the rate of carbon gasification relative to the rate at which carbonaceous deposits are formed. However, high steam to carbon ratios are detrimental to the thermal efficiency of the process.

In the case of the French process, developed at the Societe de la Grande Paroisse, a fluidized bed reactor was used. The reactor was designed to process or react heavy sulfur-containing raw materials (for example fuel oil) into hydrogen without removal of sulfur and minimal carbon formation. In this process, water and hydrocarbons are fed into a fluidized bed of a nickel-containing catalyst held isothermally at 1073 to 1194°K. The fluidized bed operation allows operation at low steam/carbon ratios. However, the heavier raw materials cause some hydrocarbon breakthrough. Furthermore, for two reasons it is not desirable to have a non-containing catalyst in the fluid bed process. The first reason is that wear or abrasion in the bed results in the loss of the expensive nickel-containing catalyst. The second reason is extensive soot formation and sulfur poisoning of nickel in the catalyst, which occurs when treating heavy liquids that tend to form soot and contain a significant amount of sulfur (No. 4 and No. 6 fuel oils).

In addition, certain reacting materials will cause special challenges for the reactor, the process and the system design. Lye, which is the byproduct of pulping processes, generally contains biomass-derived lignins and inorganic sodium and sometimes, as in the case of the kraft fluid, sulfur process chemicals. The economics of the process dictate the need to recover the process chemicals and the energy values of the lye.

For example, Kraft's lye recovery process must provide a facility to conserve and/or regenerate sulfur in the sodium sulfide form. This is currently carried out using a Tomlinson recovery furnace, where lye is burned and the inorganic sulfate chemicals are reduced by reaction with carbon in a molten bed at the bottom of the furnace. Although the Tomlinson furnace has been widely used in Kraft's paper industry for several decades, it has significant disadvantages, including safety hazards, i.e. meltwater explosions, corrosion and unwanted environmental emissions. In addition, the Tomlinson furnaces represent a significant part of the total capital expenditure in a modern mill. When mill expansions are to be carried out, there is little opportunity to increase factory capacity expansion since recovery boilers are only economical in relation to large capacities.

For these reasons, the paper industry has searched for new technology alternatives as a replacement for the Tomlinson recovery boilers. Gasification of lye can be carried out autothermally, but this method results in product gas with a low calorific value and in most cases such autothermal gasifiers will produce a molten melt. More importantly, since Kraft's chemicals must be recovered in a reduced state, direct exposure of lye to oxidants, for example by partial oxidation and autothermal processes, is generally undesirable. Others have demonstrated autothermal gasification of lye in a molten salt reactor. Although reduction of Kraft's chemicals with carbon contained in the molten salt has been established in an autothermal gasifier, this process suffers from many of the same difficulties associated with the Tomlinson furnace technology, including melt production, corrosion problems, explosion risks, high capital costs and low system efficiency.

Thus, there is a need for a liquor recovery process that avoids the need for molten metal handling, provides high reliability and safety, high thermal efficiency, low cost, and is compatible with low modular system designs to support small increases in mill expansion.

For several applications, there is a need for both new reactor technology for indirectly heated thermochemical processes, and for the various endothermic processes, optimization of the reactions and process parameters to maximize yield. The need for new technologies and processes for indirectly heated thermochemical reactors is present in a very wide range of end-user applications, including for example mild gasification of coal, steam gasification of coal and peat, thermal cracking of chemicals, thermochemical treatment of industrial and municipal waste , gasification of energy-containing waste streams from food processing factories, recovery of useful fuel forms from oil waste and oil and tar sands, detoxification of energy recovery from hazardous waste materials and general streamlining of endothermic reactions in chemical processes for the production of desired chemicals .

Advantages in heat emission and heat transfer rate can be achieved by the use of pulsating combustion chambers. The combustion intensity of the pulse combustion chamber is high. For a given heat output, the combustion chamber is relatively small. Since the combustion products are driven by combustion-induced oscillations, the boundary layer resistance to heat transfer from the fuel gas to the inner wall of the combustion tube (resonant tube) is further reduced and the heat exchange surfaces can be correspondingly smaller for a given yield. For example, US patent 4,655,146 refers to a reactor for carrying out high temperature reactions such as melting, heat treatment and combustion. The reactor comprises a combustion chamber, or an extension thereof, tuned to resonate and thereby achieve efficient combustion. Fuel and the reaction material are fed into and undergo reaction inside the chamber. US patent 3,606,867 refers to a pulsating combustion system for producing a high-temperature and pressurized gas flow impinging on objects to be heat-treated. US patent 2,937,500 refers to resonance jet engines in combination with heat exchange equipment, which equipment is characterized by a sonically increased speed of the product transfer for use in heating the air supply to the engine. These patents are incorporated herein by reference. None of these patents or any of the aforementioned thermochemical processes suggest the use of pulsed combustion in connection with an indirectly heated fluidized bed reactor.

The present invention overcomes the shortcomings of the currently used indirectly heated reactors by using a single or, preferably, several resonance tubes for a pulsating combustion chamber which exits from the same combustion chamber as in the bed heating exchanger, and where the speed of the pressure oscillations of the combustion gases and the intense acoustic field radiated by the several resonance tubes into the reactor bed increase the rate of heat emission, heat and mass transfer and finally the reaction rate in the bed.

It is an object of this invention to provide thermochemical reactors characterized by high thermal efficiency, high processing rates, low capital and maintenance costs and high product quality for end-use applications, including:

Gasification of lye

Steam reforming of heavy liquid hydrocarbons

It is another object of this invention to provide a thermochemical indirectly heated reactor apparatus and method for increasing the rate of heat release, heat and mass transfer, reaction rate and throughput to produce useful products and detoxification of materials with low levels of environmental influence.

It is another object of this invention to provide improved thermochemical processes for end-user purposes, including:

Recovery of lye

Catalytic steam reforming of heavy liquid hydrocarbons

It is another object of this invention to generate medium Btu gas of approximately 13 to 20xl0<6> J/m<3> and hydrocarbon liquids from alternative energy sources such as coal, oil shale, biomass, municipal waste, energy-bearing industrial waste and waste hydrocarbons with negligible production of unwanted tar substances and heavy oils.

It is also an object of this invention to provide an apparatus and a method for gasification of lye and recovery of its energy and chemical values without molten metal production.

Another object is to provide a modular lye recovery system and process suitable for small

extensions or increases in mill capacity.

Additional purposes and advantages of the invention will appear from the following description, and will be partially obvious from

background of the description, or they will appear during the practice of the invention. The purposes and advantages of the invention are achieved by means of the features and combinations which are specifically pointed out in the subsequent patent claims. Thus, the invention is defined in its five aspects by means of the attached patent claims.

In order to achieve the objects in accordance with the purpose of the invention, as carried out and broadly described herein, the present invention comprises an indirectly heated thermochemical reactor apparatus which includes a fluidized bed reactor which is indirectly heated by a pulse burner having a combustion chamber, an aerodynamic valve , and a single or several elongated conductors which form a resonance zone, and which have an inlet at the combustion chamber at one end and an outlet at the other end, hereinafter called "resonance tube". The fluid bed reactor is equipped with one or more material introduction ports and is fed with solid particles comprising a suitable bed material which may be inert or of a catalytic nature which provides a catalytic increase of the reactions in the bed. The fluid bed reactor is also equipped with a port near the bottom of the reactor for the introduction of a fluidizing medium which can be steam, gas, vaporized liquids of a different type than water vapor or combinations thereof. The flow of the fluidizing medium in the fluidized bed reactor is distributed in a manner that is substantially equal across the cross-section of the bed by means of distribution devices for equal distribution of the fluidizing medium. At the outlet of each resonance tube, an outlet space is arranged to collect gases flowing out of the resonance tubes. Solid material, gases and vapors, hereafter called "reactor products", escape through the fluidized bed reactor through a separate port. The reactor products then enter a special separation device such as a separator or a filter chamber or another suitable device to separate solids from the reactor products.

The operation of the apparatus according to the invention involves the introduction of a fuel and an oxygen-containing gas into a combustion chamber and the combustion of a first portion of the fuel introduced into the combustion chamber under conditions which effect pulse combustion and thus produce a hot gas stream comprising the remaining portion of the fuel introduced into the combustion chamber, and the pulse combustion operates to produce velocity oscillations of at least a frequency of about 20 Hz, and acoustic dynamic pressure levels of at least about 165 dB. The hot gas flow from the combustion chamber is then led into an inlet to an elongated resonant zone delimited by a conducting wall which has an inlet at one end and an outlet at the other end. The remaining part of the fuel in the hot gaseous stream is burned in the resonance zone and thereby additional heat is produced in a combustion product stream. Heat is transferred from the combustion product stream through the conductor wall surrounding the resonance zone into a bed of solid particles bounded in a reaction zone. A fluidizing liquid vapor or gas is injected into and through the reaction zone via a port at a rate necessary to maintain the solid particles in an agitated state. The solid particles in the reaction zone are heated by heat transfer from the combustion product stream in the resonance zone without direct contact between the combustion product stream and the particles, so that the total rate of heat transfer from the combustion product stream to the particles is at least twice as high as the rate that could have been obtained in the absence of the pulse combustion.

A reaction material is introduced into the reaction zone through one or more ports and mixed with the heated solid particles and fluidizing medium of the bed, and thus undergoes an endothermic reaction or physical change in the bed and is processed to yield useful products. The intense acoustic field radiated into the bed by the solid particles in the reaction zone, from the resonance tubes, increases the mixing in the bed and the reactant allowed and increases the rate of particle-to-gas and particle-to-vapor mass transport and reactions in the bed, thereby reaction diffusion limitations are overcome, and the increase in the efficiency of the reaction kinetics results in high process throughput rates.

Pulsations in the flow of combustion gases through the resonance tubes result in strong mass transfer within the boundary film bed at the interface between the hot combustion gases and the inner conductor wall, thereby eliminating a significant cause of heat transfer resistance. The heat transfer rate between the outer wall of the resonance tubes and the material in the reaction zone (fluidized bed) is usually high. The indicated heated system of this invention has a heat transfer coefficient that is higher by a factor of about 2 to about 10 times the heat transfer coefficients of conventional systems. As a result, the size and number of resonant heat transfer tubes in this invention are relatively small compared to the size and number of heat exchangers in conventional indirectly heated combustion tube systems.

The combustion chamber is also compact due to efficient combustion and high volumetric heat release rate. The pulse combustor of the apparatus of this invention has a heat release rate of about 41.lxl0<6> to about 62.lxl0<6> W/m± or higher, which is comparable to the heat release rate of 41.4xl0<4> to about 41, 4xl0<5 >W/m± for conventional combustion chambers. In the preferred embodiment of this invention, the pulse combustor has an aerodynamic valve for self-regulating the fuel to air ratio within the combustor's combustion area and produces heat of 41.4xl0<6> W/m+, and a combustion product gas temperature of approximately 1922 K, gas velocity in the resonance tube of at least 91 m/s with oscillations of at least 165 dB, and at least 20 Hz, and radiates an acoustic pressure level of at least approximately 14 0 to 150 dB (measured in the reaction zone). As a result of the intense acoustic field, many reactions take place in the reactor according to the invention at reaction zone temperatures of 56 to 111 K lower than in conventional systems.

This invention also advantageously uses pulse combustion to achieve complete combustion of highly flammable fuels. The fluctuating flow field causes the products of combustion to be swept away from the burning, non-gaseous fuel, thus providing access to oxygen. Diffusion restrictions in the pulse combustion chamber and resonance tube are essentially avoided, which reduces the need for excess air.

A wide range of reactors and layer materials can be used in the invention. In the various aspects of this invention, a fluidized bed reactor or an entrained bed reactor is used. The reactor according to this invention can be used for heating a number of varieties of inorganic or organic materials, including, for example, waste oils, sludge and lye.

In accordance with a particular aspect of this invention, steam gasification of lye is carried out without process air or oxygen, and thus only endothermic reactions take place in the bed. The process in this invention makes it possible to carry out lye recovery without the formation of a melt.

In this aspect of the invention, liquor having a concentration of between about 50 to 75% solids is steam atomized or sprayed directly onto the hot bed solids in the fast ion zone of the reactor. The lye forms a relatively thin coating on the surface of the solid particles and is pyrolysed at a very high rate. This provides a high surface area and porosity for the rapidly porylyzing lye coating which is sufficient to complete steam gasification, sodium sulphate reduction to sodium sulphides in the reactor's reducing environment and to release sulphur-containing hydrocarbons found in the lye in the form of hydrogen sulphide, and where in essentially all the sodium in the lye has reacted to form sodium carbonate, without melt formation.

The preferred bed material in this embodiment, which material is initially charged in reaction zones sodium carbonate (soda ash). In this embodiment, the preferred reaction zone temperature is 856 to 950 K with the bed heating element surface maintained below a maximum temperature of about 978 to 1005 K. This is essential to prevent softening or melting of the sodium carbonate present in the bed, which would lead to bed agglomeration and formation of unwanted melt.

In order to recover the sulfur released from the reaction zone together with the product gas, the recovered sodium mixture, which is in the form of sodium carbonate with a small portion of charred mass, is dissolved in water to form an alkaline sodium carbonate solution which becomes used to wash the product gas and thus recover the sulfur and form another fraction of lye. This liquid is further processed in the usual manner to provide sodium hydroxide and sulphide (white liquor) for the kraft pulp process. Traces of hydrogen sulphide which may be present in the product gas after washing the gas with the sodium carbonate solution can be removed by washing the gas once more with sodium hydroxide if necessary.

In another aspect of this invention becomes

a heavy liquid hydrocarbon fuel, including, for example, No. 2 fuel oil, logistic military diesel and jet engine fuel, No. 4 fuel oil, and residual fuel oils such as No. 6 and Bunker C fuels, and steam introduced into the reaction zone containing a bed of solid calcium aluminate based catalyst or another catalyst that withstands sulfur poisoning by steam activation and carbon gasification.

The preferred bed temperature for the hydrocarbon vapor reforming reactor is in the range of 1150 to 1250 K. The heavy liquid hydrocarbon fuel is atomized directly onto the hot catalyst particles which are fluidized by steam injected near the bottom of the bed. The hydrocarbon fuel covers the surface of the hot particles in the bed and evaporates very quickly, thus giving little or no chance of cracking and soot formation. The catalyst present in the bed activates the steam which reacts with the hydrocarbon steam at the high bed temperature and a rapid steam reforming of the fuel occurs which forms a hydrogen-rich gas containing methane, carbon monoxide, carbon dioxide and smaller amounts of higher hydrocarbons. The product gas also essentially contains the entire sulfur content of the fuel in the form of H2S. The product gas containing light elements was then washed to remove hydrogen sulphide and it was further processed in a conventional second stage fixed bed (plug flow) steam reformer to steam reform the betane and trace higher hydrocarbons to maximize hydrogen production. Alternatively, the product gas can be washed for hydrogen sulphide and used as a high-quality hydrogen-rich gas for combined cycle and fuel gas turbines. In this alternative, inferior fuels can be used to feed both the reaction zone and the combustion zone, which makes it possible to use cheaper fuel to drive fuel gas turbines and combined cycle gas turbine systems.

In this aspect of the invention, a number of serious cost and operational problems found in the THR reformer are avoided. In this embodiment, the fuel is atomized directly on the hot fluidized bed material with vigorous mixing in the fluidized bed and high rates of fuel vaporization and immediate reactions with the activated steam fluidization of the catalyst bed. therefore no special equipment is required to properly feed and mix as well as vaporize the heavy raw materials which is the case with the THR fixed bed reactor. In addition, the product transfer between the heating element in the bed and the fluidized bed of this invention and within itself

the fluidized bed must be very high. This entails a reduction in equipment size and material costs by a factor of around 2.5 to 3 when it comes to capital cost reduction.

The reliability of the system is also greatly increased with this invention compared to the THR system. In the case of THR fixed bed reformers, feedstock vaporization and proper mixing must be ensured to avoid operating problems at the inlet to the fixed bed reformer, and especially with heavy feedstocks, soot will form and settle on the catalyst in the fixed bed. This in turn leads to more residence time for the fuel without it being available to the active catalyst surface near the inlet of the pipe (due to soot coating), at high temperatures which causes the fuel to be vapor cracked and form more soot. This failure mode increases with progressively more soot that forms downstream of the tube inlet and eventually clogs the fixed bed tubes.

In this aspect of the invention, small sub-quantities that can be formed will not lead to increased errors in the process. Due to the agitated condition of the fluidized bed, the bed material is constantly moving within the bed and soot coated catalyst particles will eventually move close to the distributor which brings the local steam to carbon stoichiometry to be very high. The incoming steam gasifies the soot and produces synthesis gas without operational problems. Even in the case of a lot of soot formation, the fuel flow can be temporarily reduced while the steam injection rate is maintained and thus all the soot in the bed is steam-gasified without stopping the gas production of the system, or the fluidized bed can be drained or emptied and at the same time be filled with fresh catalyst mass under operation, an option not available with the case of THR fixed bed reforms. The first-stage fluidized bed for this embodiment of the invention is thus a reliable and more operationally robust and efficient when treating heavy, liquid fuels into lighter species that can be washed for hydrogen sulphide if necessary and further steam-reformed in a fixed-bed second stage on the the conventional way where the second stage catalyst may contain nickel. This is simply due to the fact that the second stage fixed bed has a plug-gas flow. In the French single-stage fluidized bed, the characteristic mixing in fluidized beds and hydrocarbon breakthrough will compromise reactor performance. In this aspect of the invention, the second stage is exposed only to lighter hydrocarbons and little or no sulfur along with significant hydrogen partial pressure (45-65 volume percent) which allows the use of nickel in the catalyst for efficient steam reforming of lighter hydrocarbon species that break through the fluidized bed reactor at reasonable second stage reactor temperatures.

The invention will now be described with reference to the drawings, where

Fig. 1 shows the indirectly heated thermochemical

the reactor apparatus according to the invention.

Fig. 2 shows a temperature profile along the length of the heat exchange resonance tubes of the invention compared to the temperature profile of conventional combustion tubes without pulse combustion. Fig. 3 shows the preferred U-tube resonance tube design for the integrated pulse-burner fluidized bed thermochemical reactor according to the invention. Fig. 4 shows the elements of the pulse combustor used for indirect heating of the fluid bed reactor according to the invention. Fig. 5 shows a recovery device for black liquor according to

the invention.

Fig. 6 shows a flowchart for the recovery process for black liquor according to the invention.

Reference will now be made in detail to the currently preferred embodiments of the invention, which together with the following examples serve to explain the principles on which the invention is based.

With reference to figure 1, the thermochemical apparatus includes a fluid bed reactor 1 which is indirectly heated by means of a pulse burner 2 which has a combustion chamber 3, an aerodynamic valve 4, and a single or several elongated conductors 5, and which delimits a resonance zone and has an inlet at the combustion chamber at one end thereof and an outlet at the other end.

The fluid bed reactor 1 is equipped with one or more material introduction ports 6 and is charged with massive or solid particles comprising a suitable bed material 7 which can be inert or of a catalyst nature which provides a catalytic increase of the reactions in the bed. The fluidized bed reactor is also equipped with a port 8 near the bottom of the reactor for the introduction of a fluidizing medium which can be steam, gas, evaporated liquids of a different type than steam or a combination of these. The flow of the fluidizing medium in the fluidized bed reactor is distributed in a manner that is substantially equal across the cross-section of the bed by means of distribution device 9, which is indicated in the figure as a distributor plate, but which can also be a number of nozzles or pipes that have metering holes for equal distribution of the fluidizing medium.

At the outlet of each resonance tube, an outlet space 10 is arranged to collect gases that escape from the resonance tubes. Reactor products are removed from the fluid bed reactor through a separate port 11. The reactor products then enter a special particle separation device 12, indicated in figure 1 as a separator, but which can also be a filter chamber or another suitable device for separating the solids from the reactor products.

The operation of the apparatus shown in Figure 1 involves introducing a fuel and oxygen-containing gas into it

the combustion chamber 3 and burn a first part of the fuel which is introduced into the combustion chamber 3 under conditions which effect pulse combustion and thus produce a hot gaseous stream which comprises a remaining part of the fuel which is introduced into the combustion chamber 3, and the pulse combustion works so that

velocity oscillations of at least 20 Hz, and dynamic acoustic pressure levels of at least approximately 65 dB are produced in the combustion chamber. The hot gaseous flow from the combustion chamber is then led out into an inlet to an elongated resonance zone delimited by a conductor wall, which has an inlet at one end and an outlet at the other end. The remaining part of the fuel in the hot gaseous stream is burned in the resonance zone, thereby producing additional heat and a combustion product stream. Heat is transferred from the combustion product stream through the conductor material which surrounds the resonance zone into a bed of massive particles 7 which is delimited in a reaction zone. A fluidizing liquid vapor or gas is injected into and through the reaction zone through port 8 at a rate which works to maintain the solid particles in an agitated state. The solid particles in the reaction zone are thus heated up

the heat transfer from the combustion product stream in the resonance zone so that the total rate of heat transfer from the combustion product stream to the solid particles is at least twice as high as what could be achieved in the absence of pulse combustion.

A reaction material is introduced into the reaction zone through one or more ports 6 and is mixed with the heated solid particles of the bed and the fluidizing medium and then undergoes an endothermic reaction or a physical change in the bed and is transformed into usable products. The intense acoustic field that is radiated into the bed of solid particles 7 in the reaction zone from the resonance tubes 5 improves the mixing of the bed and the reaction material fed to it and increases the rates of mass transport and reactions in the bed resulting in higher process throughput rates.

The reactor of this invention is preferably made of carbon steel coated with refractory material, but it may also be made of a high temperature alloy capable of withstanding temperatures of up to about 1255K and at pressures of up to about 12 atmospheres (IO< 6> Pa). In the case of high-pressure operation, the reactor is preferably designed cylindrically. Referring to Figure 5, the reactor diameter or width 22 may vary from less than about 0.3 m to greater than about

3 m. The reactor height 2 3 can vary from less than about 1.5 m to greater than about 15 m. Height to diameter or

the aspect ratio of the reactor is preferably kept in the range from about 1 to about 10. The reactor operates at a pressure ranging from close to atmospheric pressure to about 12 atmospheres (10<5> Pa to 1.2xl0<6> Pa) and the operating temperature is in the range from about 783 to approximately 1255 K depending on the type of raw material and the desired products.

In this invention, a wide range of reactors and bed materials can be used. A fixed bed material can act both as a heat receiver and catalyst for the desired reaction. The use of a particular type of reactor bed depends on the reacting material, the process being carried out, and the desired products. The bed material can be a carbonaceous material, including for example a mixture of inorganic material and carbonaceous material or a mixture of bed material and feedstock material for reshaping, or feedstock material sludge such as lye. The size of the bed material is preferably in the range of about 50 to about 500 µm.

This fluidizing gas, for example steam is injected into and passes through the bed material at a surface velocity of about 0.3 to about 3.0 m/s. The bed material thus undergoes fluoridation, i.e. that the particles in the bed material undergo mixing and are maintained in a continuous state of agitation. The density of the fluidized bed varies with the velocity and viscosity of the fluidizing gas or medium and the size distribution as well as density and shape of the bed particles. The fluidizing gas can be fed to the reactor by means of a blower, a compressor or a pump through a gas distribution plate, nozzles or spreader tubes, preferably at a pressure slightly higher than the average reactor pressure to compensate for pressure drops caused by the distribution device, the bed material and downstream pipes.

By the term agitated state as used herein, is meant the state in which the solid or massive particles are when they are in a moving, fluidized, or entrained bed and airborne by a flowing gas, or in a mud bed. By the term agitated motion as used herein is meant the motion of the solid particles when they are in an agitated state.

After the bed of solid particles assumes a uniform fluidized state in the reactor, air and fuel are fed to the pulse burner. The fuel can be a liquid, gas, solid or a mixture of these. Preferably using a liquid fuel such as heavy fuel oil, or a gaseous fuel such as natural gas, or a synthetic gas; but a solid fuel, for example coal, charred coal, biomass or charred biomass can also be used. As fuel enters the pulse burner, combustion is initiated by a spark or a gas fired igniter.

The reaction products and part of the fluidizing mass leave the reactor through a line at the top of the reactor. Entrained solid particles from the bed and fast

reaction products, if there are any, can be separated in a separator and are returned to the reactor. Part of the gaseous stream of reaction products and fluidization gas, which is now free of entrained solids, is preferably recycled to the reactor for fluidization purposes. If the product gas contains a condensable component, preferably at least a part is cooled to condense condensable components which are then transferred to a product recovery zone.

As shown in Figure 4, the pulse burner mainly consists of three components; 1) air inlet valves 59, preferably aerodynamic valves rather than mechanical or flap valves, 2) a combustion chamber 60 having a fuel injector 61, and 3) one or more end tubes or resonance tubes 62. Fuel and air enter the combustion chamber and an ignition source firing the mixture. The steady increase in volume caused by the rapid rise in temperature and development of combustion products pressurizes the chamber. As the hot gas expands, the aerodynamic valve will act as a fluid diode and allow a preferential flow in the direction towards the resonance tube.

Several different types of pulse burners are used in the apparatus and method of the present invention, including Helmoltz, Schmidt and Rijke tubes. Helmholtz type combustors are preferred because of their excellent combustion performance and the highly resonant nature of the Helmholtz design, which tends to produce the highest pressure fluctuations per Btu/h when burning in a given combustion chamber volume. The resulting high level of flow oscillations effectively improves combustion and provides a level of thrust useful in overcoming pressure drops in heat exchange and other downstream ash removal subsystems.

At least two types of air inlet valves can be used. Although mechanical valves provide somewhat higher disc pressure, the reliability of these valves is usually low, and this is especially true in solid fuel applications. Combustion of solid fuels is more likely to result in ash deposits that destroy valve seats in mechanical systems. Erosion, corrosion and metal fatigue further limit the use of mechanical valves. Aerodynamic valves that have no moving parts are therefore preferred for their high reliability and low maintenance.

The intrinsic stoichiometry of the pulse burner can be determined by design by experts in the field on the basis of what is described here and it will be relatively constant over a wide range of burning speeds. At the lower end of this combustion area, combustion-induced pressure fluctuations in the chamber are lowest. Therefore, the amount of air intake induced by the fluid diode (the aerodynamic valve) in response to dynamic pressure fluctuations in the combustion chamber is the lowest. As the fuel feed rate is increased, the amplitude of the pressure fluctuations in the combustion chamber is increased due to the increase in heat release responsible for the excitation of the dynamic burner induced pressure. This, in turn, will result in more air intake through the aerodynamic valve. The burner's working stoichiometry is therefore automatically maintained over an area of combustion without the need for active control and coordination of the combustion air and fuel mass flow rate.

The primary function of the aerodynamic valve is to act as a fluid diode that uses pressure fluctuations in the combustion chamber to induce intake of the combustion air. Two parameters dominate the design of an aerodynamic valve, i.e. the minimal resistance of the air intake and the fluid-diodicity of the valve. The latter is a non-dimensional ratio between the resistance to flow out of the chamber and the resistance to flow into the chamber (intake). In general, the higher the fluid-diodicity of the aerodynamic valve, the more air per Btu/h of fuel combustion is induced by the intake. A burner that normally works with a lot of excess air will therefore, when using a valve with a high minimum resistance to air intake (smaller minimum throat diameter), work at a lower air stoichiometry by throttling the air intake in the inlet. With a fixed inlet damping setting, the combustor firing rate can be varied by the induced stoichiometry that remains and is essentially constant over a combustion region.

It is also possible to reduce the lowest burning speed of a combustion chamber by reducing both the aerodynamic valve and the minimum diameter of the resonance tube. This also improves the start-up properties of the combustion chamber. With this design choice, the screw-down ratio can be greater than 8 to 1. However, this may require an air inlet fan if the pressure drop downstream in the system requires this. Nevertheless, the air intake (mass flow rate) is dependent on the burning rate since the self-propulsion and thrust distribution of the pulse burner unit are in effect. This system design tends to increase the maximum burning intensity that can be achieved for two reasons. Firstly, with the higher flow resistance at both ends of the chamber, a higher dynamic pressure amplitude will be achieved. Second, the presence of an air fan in the air intake will tend to allow "supercharging" of the burner to higher burning rates than can be achieved under atmospheric drags.

Pressure fluctuations typically range from 13.8 to 34.5 kPa, peak to peak. These fluctuations are mainly sinusoidal and at frequencies characteristic of the Helmholtz/quarter-wave fundamental mode of the burner. These pressure fluctuation levels are on the order of about 165 to about 190 dB in sound pressure level. Sound intensity measured up to the resonant tube wall is in the range of 140 to 150 dB. The acoustic field frequency range depends primarily on the combustion chamber design and is only limited by the fuel's combustibility characteristics. In general, the geometry of the resonance tube (diameter, length, single or multiple tubes, etc) and the volume ratio between the resonance tube and combustion chamber will affect the frequency of the produced acoustic field. The oscillation frequency is given by:

where

C = the speed of sound

Vc = volume of the combustion chamber

Lt = length of end pipe

Vt = is the volume of the end pipe

In general, shorter pulse burners will be required for higher frequencies.

The geometry of the combustor can be chosen to affect the portion of the fuel that burns and helps induce the pressure oscillations, and the portion that is burned downstream of the dynamic pressure peak region under the influence of the induced oscillatory flow conditions. The burning speed in the combustion chamber is dominated by vortices that are released from the transition in the cross-sectional area of the chamber. In the resonant tube, however, the burning rate is dominated by the axial oscillating flow velocity component which tends to increase monotonically from the resonant tube inlet to the outlet.

The combustion process in the resonance tube is most responsible for completing the burning of charred mass produced by larger particles that are vaporized and partially burned upstream in the chamber. The increase in the oscillation speed along the resonance tube maintains a high rate of burning of charred mass since the mass particles are carried along to a greater extent and since the 02 partial pressure decreases. In stable flow combustion systems, the relative movement between the gases and the solids depends on eddies, turbulence etc, and these flow fields tend to be attenuated downstream of the flame in the area where they are most needed.

In the case of the conventional combustion chamber and conventional combustion tubes, essentially all the fuel is burned in the conventional combustion chamber and the heat from the combustion is given off to the flue gas. Thus, the heat of combustion will be carried by the hot flue gas in the form of sensible heat. Heat is then transferred from the hot flue gas through the combustor walls to the reactor material over the length of the combustor and causes the flue gas temperature to steadily decrease as shown in Figure 2 for the conventional combustor and combustor case. The heat transfer is mainly radiation near the inlet to the combustion tube where the flue gas temperature is sufficiently higher than the combustion tube wall and the reactor temperature. Further downstream in the fire tube, as the flue gas temperature becomes lower, the heat transfer becomes more and more dominantly convective as shown in Figure 2. The rate of change in the flue gas temperature for the case of the conventional fire tube is proportional to the local heat transfer flux at a given distance along the length of the tube. As shown in Figure 2, this rate of change is steadily decreasing as the temperature difference between the flue gas and the reactor temperature decreases. Furthermore, near the outlet of the combustion tube, as the flue gas temperature is low and the gas velocity is slower, the convective heat transfer coefficient between the flue gas and the inner wall of the combustion tube will be lower, and thus the heat flux, which is a function of both the temperature difference between the flue gas and the bed temperature and the heat transfer coefficient will be even lower.

In the case of the pulse combustion chamber, where the combustion tubes are the resonance tubes of the pulse combustion chamber, only a part of the fuel will be burned in the combustion chamber, especially if low-grade, fat fuel is used, and thus the temperature of the combustion products at the inlet to the resonance tube will generally be lower, as shown in figure 2. This allows the use of less expensive materials for the resonance tube compared to the material required to withstand higher flue gas inlet temperatures in the case of the conventional combustion tube.

The rate at which the temperature in the flue gas falls along the resonance tube is also lower than in the case of a conventional combustion tube, as shown in figure 2. This is due to the continued combustion and thus the heat release in the tube section near the inlet. This does not compromise the final fuel conversion efficiency in the pulse combustor due to the vigorous mixing caused by combustor-induced flow oscillations that take place in the resonant tubes of pulsating combustors that complete combustion in the tubes. The slow reduction in the flue gas temperature in this area, indicated as continued heat emission in Figure 2, ensures a high heat flux and heat transfer in the area with a net gain compared to conventional combustion tube systems, which is generally due to higher mean temperature differences between the flue gas temperature and the reactor temperature in this region and the dominant higher radiant heat transfer component present.

Past the continued combustion chamber area, the smoke or fuel gas temperature in the resonance tube will decrease monotonously. Nevertheless, in the case of the resonant tube of a pulse combustor, the dominant convective heat transfer in the balance of the tube length will be higher than would be the case in a conventional fire tube.

The smoke or fuel gas flow in the resonance tube has two velocity components. One is the mean flow velocity and the other is an oscillatory component that increases monotonically in amplitude from the resonant tube inlet to the outlet. The average velocity of the flue gas in the resonance tube of the pulse burners used in this invention is generally higher than that which can be found in conventional fire tubes. This is primarily due to the combustion-induced pressure thrust that develops in the combustion chamber of these pulse burners. This pressure thrust, or a mean pressure increase, develops as a result of the oscillating pressure in the combustion chamber of a pulse burner and the fluidic diodicity of the aerodynamic valve. The thrust pressure in the chamber can develop smoke or combustion gas velocities of at least 305 m/s without the need for pressurized combustion air or introduced draft fans. The higher average flow rate in the resonance tube will in turn be the basis for higher film speeds and thus higher heat transfer coefficients between the flue gas and the inner wall of the resonance tubes.

In addition, the oscillating flow rate component, which increases monotonically in amplitude from the resonator tube inlet to the outlet, will further enhance the convective heat transfer between the flue gas and the inner wall of the resonator tube. As the temperature of the flue gas falls monotonically over the continued combustion and heat release region in the resonant tube, the heat transfer coefficient due to the monotonically increasing amplitude of the oscillating flow rate component increases. This increases the heat flux in this area with flue gas discharge temperatures lower than that achieved with conventional fire tubes of the same size. The lower flue gas temperature of the smoke escaping from the resonance tubes improves the thermal efficiency of the system since more heat was extracted from the flue gas and transferred to the reactor bed to support the endothermic reactions taking place in the bed.

The design of the resonant tube may in principle involve complex generators, but this is not necessary, i.e. that a straight line generator forming a tubular or conical section is quite practical. This degree of freedom allows control of the gas outlet rate and the total volume of the resonance tube for a given length. The volume of the resonant tube affects the resistance time available to complete the burning of charred mass produced by larger particles as well as the resonant frequency of the device. In this invention, radiant heat transfer continues over a longer length of the fire tube when using solid fuels since the burning fuel particles continue to provide high luminosity focal points

as they flow and burn in the resonance tube.

There are various designs suitable for the heat transfer tubes of the present invention, including a single straight tube, multiple tubes, U-tubes, spiral tubes, and covered or shielded tubes. The size, shape and number of resonance tubes depends on the heat transfer profile required and the reactor size. In one embodiment, the combustion products are taken out through two separate resonance tubes that are introduced into the reactor. After heat exchange from the tubes to the bed material, the flue gas streams are combined in a room or manifold just outside the reactor. In a preferred embodiment, the bed's heat transfer surface comprises parallel resonance tubes 5 which have inlets in connection with the combustion chamber 3 and outlets in connection with the common space 10. In another particularly preferred embodiment, shown in Figure 3, the resonance zone comprises a single or several tubes 13 as a U-shaped bend near the top of the fluidized bed 14 and where the inlet 15 and the outlet 16 of the resonance tubes are close to the bottom 17 of the reactor 18. In this embodiment, the combustion chamber 19 is in connection with the inlet of the resonance tubes 15 and an outlet space 20 is arranged in connection with the outlet 16 of the resonance tubes. Such U-shaped resonance tubes are advantageous in that they eliminate the problems caused by thermal expansion and stresses, which can result in splitting or separation in the tube connections. In yet another embodiment, the combustion gases pass upwards through a bundle of resonant tubes having three sections. The combustion gases first pass through a straight tubular bundle section, then a helical tube bundle section and finally through a straight tubular section before being discharged. The curved tubular bundle of this arrangement provides a very large heat transfer surface, and is therefore preferred in high temperature applications.

Part of the resonant tube may be surrounded by a cylindrical screen. The shielding portion may vary in length, depending on the type of bed and raw material to be processed, which may necessitate that the temperature of the metal in contact with the bed be kept below a given

temperature, for example to avoid the formation of a melt.

A relatively stagnant gas film remains confined in the annular space between the resonance tube and the screen, thereby maintaining the outer surface of the screen below the desired temperature. In the case of lye recovery, this temperature is below approximately 1005K. The annular space may cause the average outer surface temperature of the shield to be from about 167 to 222K lower than the <g>average outer surface temperature of the shielded region of the resonant tube. The screen is useful in preventing unwanted physical or chemical changes in the bed or feedstock materials as a result of the relatively high outer tube surface temperature near the inlet of the tubes.

A most preferred embodiment of this invention is application of the invention to all types of lye recovery, especially in power lye recovery and sulphite lye recovery. The description here uses the case of lye recovery as an example since this process includes more complex the relevant process variables.

Recovery of lye

The preferred embodiment of the lye reactor 21 is shown in Figure 5. Near the top of the reactor, a product gas and outlet 24 for entrained product chemicals is arranged from the square zone of the reactor to the fluidized bed. The tubes 25 of a number of modular pulse burner units each having an output of approximately 440 to 1465 kW firing rate, depending on the size of the reactor and its throughput, are immersed in the fluidized bed. The preferred capacities for such reactors are 1, 2, 3, 6 and 10 tonnes per hour of lye solid treatment. The preferred size of a reactor to treat 6 tonnes of lye per hour at close to atmospheric pressure in the reactor is approximately 2.44 m wide, 1.5 ro deep and 5.4 m high. The preferred multiple resonance tube pulse combustor is in tandem with aerodynamic valve coupling to each tandem unit 27 for out-of-phase operation, which reduces noise to the outside and increases pressure oscillations in the pulsating combustors.

The reactors are also equipped with a device 28 for spraying the lye directly onto the fluidized bed material. The preferred fluid bed material in this embodiment is sodium carbonate (soda ash) having a particle size distribution of about 150 nm to about 600 µm, with a preferred average size of about 250 nm.

The reactor is also equipped with steam and recycled product gas injection device 29 to distribute the steam and recycled gas to fluidize the bed. The preferred vapor temperature at the entrance of the bed is about 867 to 922K and the preferred fluidization velocity is about 0.6 to 1.2 m/s.

Reference is now made to figure 6, which shows a flowchart for the lye recycling process, with the gasifier represented by the reactor 31. Here, lye is injected into a fluidized bed which is fluidized with steam and a recycled part of the product gas. Although a reasonable atomized spray quality is desirable, the spray pattern does not significantly affect the carburization performance. The feed liquor is preferably injected into the bed through a steam atomized spray nozzle.

An analysis of representative byproducts from lye processed in a commercial mill is given in Table 2. Since the feedstock typically consists of 67% black liquor solids, the feedstock is heated in a steam jacket agitated vessel. The feed pump may consist of a progressive cavity pump, or, more advantageously, a positive displacement gear pump. The lye is preferably kept at approximately 355K in the storage container. The feed line to the injector should be insulated and preferably include a steam indicator. Raw material injection can be simplified by the use of an adequate feed line with steam indication and suitable cleaning of the injector tip before switching over to lye, and the use of a simple gear pump.

For lye applications, the bed solid consists of sodium carbonate, which is the final salt produced by gasification of lye. The bed filling can consist of several types of commercial sodium carbonates. Products that differ in average particle size can be combined to provide the desired fluidization properties.

In order to prevent bed agglomeration or coking, lye should be fed into the bed with a tart temperature of about 022K and preferably about 811K. At this temperature, the carbon deposition rates will be higher than the gasification rate. The soda ash bed material should have a residual layer of carbon to prevent bed clumping. When the starting soda ash contains a very low carbon level, the entire carbon bed can be gasified by a fluidizing steam before the bed reaches the desired starting temperature. When the carbon bed disappears due to gasification, soda ash can coalesce as a result of impurities, such as NaCl and KC1. A carbon layer on the soda ash granulate may be maintained to prevent such ash coalescence. Gasification of char on the sodium carbonate solids is preferably controlled by the feed rate and temperature so that the bed establishes an equilibrium carbon of about 0.5 to 10%.

The reactor temperature is preferably kept in the range 894K to 977K to ensure that melt formation does not take place. The product chemicals can then be easily and safely removed from the bed in a solid form. Lower operating temperatures reduce steam heat losses, improve thermal efficiency and reduce the cost of the reactor's construction material. However, operating the bed at temperatures above 894K will allow economical throughput with minimal carbon waste. It is essential that the combustion tube wall temperature can be kept below the temperature at which the bed material softens (1005K), in order to prevent bed agglomeration. The bed temperature is preferably monitored in several places, and the same is done with the combustion tube wall.

The bed is preferably operated at near atmospheric pressure and with a surface fluidization velocity of about 1 m/s. Start fluidization can be achieved by injecting nitrogen gas as the steam is introduced after the bed has reached a similar start-up temperature. The lower limit of the surface velocity is approximately 0.03 m/s. Fluidization and bed temperature are stratified over the length of the reactor at or below such a rate. Under normal operating conditions, the temperature of the bed is the same throughout.

Heat is supplied to the fluid bed 31 by the resonance tubes 32 which are connected directly to the pulse combustion chamber. Smoke or combustion gases from the combustor, which exit the reactor at approximately 977K to 1033K, are sent to a water or fire tube boiler 33 for heat recovery. The product gas can also be combusted in such boilers to provide a single device for steam generation. By transferring heat indirectly, product gas with heating values of about 11 to 15xl0<6>J/m<*> can be generated from 67% lye. The preferred bed heaters in this embodiment are the resonant tubes of a pulsating combustion chamber, as described above; but this is not significant since, for example, properly shielded and controlled electric heaters are technically suitable for heating the bed and can be economical in parts of the world where electricity costs are unusually low, for example where you have hydroelectric generators. Another example of a bed heater is the use of superheated steam flowing through heat exchange tubes immersed in the fluidized bed. In the case of both the electric heating and the steam tube heating in the examples described above, there is no radiation of an intense acoustic field from the heating tubes to the reaction zone, which is beneficial to the reaction rate and bed fluidization.

The preferred gasifier reactor design takes the form of a rectangular fluidized bed with sidewall-mounted pulse combustors located at multiple heights and connected by horizontally mounted resonance tubes. This design facilitates the spread of fluidization steam and allows easy maintenance of the combustion chambers. A typical combustion chamber consists of two coupled pulse combustion chambers which are operated out of phase with each other for noise reduction. The dual module will have a nominal burning capacity of approximately 73 3 kw. Three such modules will be needed for a one ton per hour (lye solids) unit, as shown in Figure 5.

A radiation shield is preferably attached to the position of the tubes nearest the combustion chamber to reduce the tube wall temperature in contact with the bed solids and prevent their softening due to contact with a high temperature uninsulated metal tube. The product gas escapes from the carburettor and enters the separator 30 where entrained fine particles are separated from the gas stream. A portion of the product gas is recycled to the fluidized bed through the emitter 34. The main fluid for the emitter is steam which can be generated internally in a waste heat boiler 35. The balance of the product gas is cooled in a boiler type steam generator 35 and it is forwarded for power generation or process use. The heat value of the product gas varies from around 894 to 1490xl0<4> J/ro<5> and it contains as much as 65 volume percent hydrogen, and it thereby has an energy density that is several times what is achievable with autothermal systems.

Only a small part of the fed carbon is washed out of the bed. This carbon is recovered in a simple way by dissolving the recovered sodium carbonate solids. This carbon can be reintroduced into the bed and be summed in the pulse combustion chamber to provide endothermic heat for the reactor, or it can be used elsewhere in the mill. If it is reintroduced, it is advantageous to premix this with fresh lye to improve adhesion of the fabric to the bed solids and reduce premature leaching from the bed.

Discharge systems for solids for fluid bed applications are available and have documented and safe performance specifications. It is common for the reactor to be fitted with a screw-type solids withdrawal valve 37 and the solids collected at regular intervals to measure the carbon content as a function of flow to monitor specified gasification rates. Despite the fact that both sulfur and sulphate are introduced into the bed in the form of lye, the bed sulfur and sulphate levels will decrease or remain constant. The sulphide content is negligible in the bed.

The inorganic salts contained in the solids 37 removed from the bed and the separate materials consist primarily of sodium carbonate and also contain sodium sulfide, sodium sulfate, sodium chloride and residual carbon in smaller amounts. These materials are dissolved in a dissolution tank 36 to recover the inorganic salts for recycling to the paper mill. In addition, the carbon value is recovered, for example in an agitation dissolution tank 36 followed by a disc filter (not shown) for carbon recovery. One can easily penetrate the porous carbon shell to effectively dissolve contained salts. Thus, the dissolution efficiency is approximately 97.7 to 99.9%.

The mass of sulfur content in the lye raw material is advantageously emitted in the form of hydrogen sulphide. These species can be easily recovered to form green liquor via a simple washing operation. The cooled process gas is fed into a washing column where the recirculating washing liquid consists of alkaline sodium carbonate formed in the dissolution tank 36. The process gas is washed to form green liquor. The purified desulphurised product gas produced by the washing can be used as a fuel source for a boiler, a gas turbine or another unit. The green liquor can then be sent to the conventional causticization loop of the mill, where lime is added to precipitate carbonate and thus form sodium hydroxide and sodium sulphide.

The primary sulfur reactions believed to take place in the gasifier include the following:

1. Lignin -► organic sulphides + H2S

2. Organic sulfides + H20 CO, C02, H2 + H2S

3. Na2S + H2p + CO2 - Na2CO3 + H2S

4. Na2S04 + 4C0 -* Na2S + 4C02 5. H20 + CO - C02 + H2

Reactions (1) and (2) represent thermal and steam gasification steps leading to the production of low molecular weight gas species and hydrogen sulphide. Due to the catalytic nature of the inorganic salts, the steam gasification reactions will reduce the organic sulfide species to very low levels. Reaction (3) shows the carbonation of sodium sulphide in the presence of steam and carbon dioxide. This reaction becomes important when the partial pressure of the steam is high and the temperature is relatively low, as is the case in the gasifier. Reaction (4) represents the reduction of sodium sulfate to sodium sulfide via the reaction with carbon monoxide. Reaction (5) represents the water-gas shift equilibrium which primarily affects the relative ratio between carbon monoxide and carbon dioxide. Neither sodium sulfate nor sodium sulfide is stable in the carburettor environment. The net reaction for sulfate is therefore: Na2S04 + 4C0 + H20 - Na2C03<+> 3C02<+> H2S The hydrogen sulfide is then absorbed into an aqueous phase to regenerate sodium sulfide. The sodium carbonate solution generated by the dissolution of bed solids provides an ideal solution for scrubbing the product gas. Since the sodium carbonate solution thus formed is slightly basic, the acidic hydrogen sulfide species are absorbed as sodium bisulfide. This green liquor is then returned to the conventional causticization loop. About. 82% of the total amount of sulfur fed to the reactor is removed in the gas phase. Over 67% of the sulfate that is fed in is transferred to a reduced form. To put it another way, only 3% of the total sulfur input will be in a sulfate. The system according to this invention is therefore capable of generating sodium sulphide with a very high conversion efficiency.

Table 1 indicates a material balance for one tonne per hour (lye solids) caustic unit based on the flow chart. Eighty percent of the total amount of sulfur is assumed to be reduced to hydrogen sulphide in the product gas and 70% of the sulfur content in the feed liquor is reduced. The hydrogen sulphide is quantitatively absorbed in the washing process. The carbon that is discarded with the product solids is 5% and is recovered for re-injection in the carburettor.

Table 3 indicates a mass and energy balance summary for 1 tonne per hour - the unit. The balance is based on the production of fuel gas that is burned in an auxiliary boiler. As can be seen, fuel gas exports will amount to approximately 2190 kw or approximately 72% of the net energy product. Dispatched or exported steam production amounts to 710 kw or 23% of the energy product. Recoverable carbon makes up the balance of the energy product, based on the total energy output (product) in relation to the feedstock, the net thermal efficiency of the system is approximately 78.7%. If only steam export is desired, this can be carried out by burning the export fuel in the fuel gas heat recovery system. If a high-efficiency boiler is used, the net thermal efficiency for the steam export case will be approximately 67%, which efficiency exceeds or is comparable to the efficiency achievable in large-scale Tomlinson recovery boilers, despite the small size of the caustic gasification and the recycling system in the present invention.

The present invention can be designed as modular units with capacities in the range of 1 to 10 tonnes per hour. These units can be mobile mounted, they can be transported by truck or rail and they require a minimum of field assembly equipment. In this way, a particularly advantageous application of the lye gasification and recovery system according to the invention appears in the incremental carbon capacity increase in power or the sulphite wood pulp processes.

Steam reforming of heavy volatile hydrocarbons

In another preferred embodiment of this invention, the fluid bed reactor is a first stage in a two-stage steam reformer for heavy liquid hydrocarbons, including, for example, fuel oil No. 2, 4 and 6, bunker C residual fuels and coal-water sludge fuels.

In this embodiment of the invention, the first step is

a fluid bed reformer and the second stage a high temperature fixed bed steam reformer. The fluidized bed section uses a calcium aluminate based catalyst to provide the activation of the steam and partial reforming of the fuel. The fluidized bed thus functions as a first-stage reformer. The primary function of this step is to increase the activity of the steam and partially reform the feedstocks to light hydrocarbons and hydrogen before feeding into the high temperature fixed bed reformer. The fluidized bed also transforms the mass of sulfur in the fuel into H2S by producing sufficient partial pressure hydrogen. The introduction of the partially reformed fuel to the second stage of the high temperature fixed bed reformer controls the sulfur poisoning of the fixed bed catalyst.

In addition to acting as a first-stage reformer, the fluidized bed has two other important functions. The first is to provide a device for rapid evaporation and pyrolysis of the heavy fuel in the fluidized bed. To achieve this purpose, the fuel is atomized and deposited on the hot surface of the fluid bed material. The fluidized bed thus acts as a heat exchanger with direct contact. Rapid evaporation and pyrolysis of the fuel is realized by ensuring that the heat transfer between the catalyst surface and the fuel is provided by coking. Fuels as heavy as bunker C and No. 6 fuel oil have been successfully vaporized in a manner consistent with the principles of this invention.

In addition to the vaporization of fuel, the fluidized bed has another important function in that it evenly mixes the activated steam with the vaporized fuel. Superheated steam is used as the fluidizing medium and uniform mixing between the fuel vapor and the steam is quickly achieved.

Partially reformed fuel is then fed from the fluid bed (first stage reformer) to a fixed bed (second stage). The fixed bed is operated at a high temperature, above about 1170 K, and uses sulfur-tolerant catalysts that do not contain nickel (to avoid sulfur poisoning). Heat is supplied to the fixed bed by a heating device in the bed. In the preferred embodiment, the heating devices are resonance tubes for one or more pulse burners. The fixed bed preferably consists of a catalyst-packed pipe design.

A small portion of the hydrogen-rich product gas produced in the second stage can be recycled back to the fluidized bed to provide adequate fluidization of the bed as well as further reduce the tendency for carbonization and sulfur poisoning.

This embodiment of the invention exhibits several degrees of flexibility not available in existing reforming technology. Use of a fluidized bed ensures rapid evaporation of the fuel and rapid mixing with steam. Evaporation of the liquid fuel in direct contact with the heat exchanger maximizes the heat flux transfer into the liquid and thus minimizes the evaporation time, and thus the potential for carbon formation. Partial reforming of the fuel before introduction into the fixed bed reformer means that it avoids carbon production and likewise avoids sulfur poisoning of the second stage reforming catalyst.

The use of a two-stage reformer provides an important degree of flexibility in the reforming of heavy hydrocarbon fuels since it increases the control of carbon production and minimizes the potential for sulfur poisoning on the catalyst surface. The use of a fluidized bed in the first reforming stage provides several advantages related to fuel vaporization, fuel/steam mixing, and partial reforming of heavy hydrocarbons to light hydrocarbons. The fluidized bed also provides flexibility to regenerate the catalyst and prevent extensive carbon build-up.

Reference examples:

Example 1: Biomass gasification

Reference is now made to the apparatus shown in figure 1 where a biomass gasifier reactor comprises an indirectly heated fluidized bed 7, where sand or other solid materials are fluidized by means of a fluidizing gas or steam which is injected through a distribution plate or a number of injection nozzles 9 at the bottom of the bed. The cylindrical reactor has several port holes 6 for selection of biomass injection. Normally, biomass is injected into the lowest port to increase residence time. In addition to the biomass injection ports, a side gas outlet port 11 is provided at the top of the free edge part of the bed.

The pulse combustion chamber is fired upwards with the fuel injected into a combustion chamber 3 below the reactor. The pulse combustion chamber in this design has 12 resonance tubes that go out from the combustion chamber (on the diagram, for the sake of simplicity, fewer tubes are shown). The heat transfer coefficient in the bioassay gasifier is typically in the range of 170 to 227 W/m<2>K, which represents an increase of at least about 50% compared to steady flow conditions found in conventional fire tube systems. However, the rate of heat release in the pulse combustion chamber system is much higher than with conventional systems. Therefore, the heat transfer rate is in practice several times higher than for conventional systems.

Product gas from the fluidized bed and smoke or combustion gas from the combustion chamber are sent through separators to collect charred mass and washed out bed material. The fuel gas from the pulse combustion chamber can then be used for superheating of steam.

Compressed air is fed by a compressor to start up the pulse combustor. Air is injected into the combustion chamber before the fuel is admitted and with the combustion chamber's spark plug screwed on. Fuel is then introduced and the pulse burner started. The preferred fuel for the burner is biomass and charred biomass supplemented to a small extent by the product gas. Combustion of the solid particles into • charred mass and biomass is carried out in the resonance tubes. Conventional burners, which are designed to provide sufficient residence time to almost completely burn the char and biomass, significantly increase total capital costs due to their size, pressure drop requirements (especially in the case of fluidized beds), and the significant isolation required for to reduce the heat losses from the large burners. Using only product gas to entertain the endothermic heat of reaction reduces the capital costs of the burner, but this also reduces the yield of net product gas from the gasification plant. Using pulse combustion, biomass and charred mass can be burned directly in the burner with only a small part of the product gas. Charred mass and biomass are thus burned efficiently in the same compact burner at high heat release rates (40-60 MW/m<5>). This also increases the radiant heat transfer in the resonance tubes due to the luminous burning of the charred mass of these solid fuels.

At the bottom of the reactor where the biomass is directly injected into the bed, the heat transfer between the bed material and the material being treated is very high, which is characteristic of fluidized beds. This results in very high rates of devolatilization (not volatilization) and pyrolysis. This in turn results in the formation of charred mass which is extremely porous. Combustion of charred biomass sbm has a high degree of porosity is easier than combustion of non-porous charred particles. High devolatilization rates also tend to produce higher quality gas, which leaves the char mass and propagates rapidly through the fluidized bed to the reactor outlet. Steam used to fluidize the bed can also react with the heavier species and carbon in the char to produce lighter products. All of these processes are endothermic and produce higher quality products if carried out at a higher rate. The availability of higher rates of heat transfer and the intense acoustic field radiated into the reaction zone support such high reaction rates.

Compressed air can also be used to fluidize the bed, including autothermal operation during heating with the pulse burner operating at full capacity. This helps bring the bed up to temperature quickly. Biomass can be fed into the bed when the bed temperature reaches approximately 588K. in general, it is not necessary to burn biomass in the bed since the heat transfer in the pipes is high and the bed can be brought to operating temperature in a short time without autothermal fluidization.

When the bed reaches the operating temperature, air fluidization is stopped and the system is switched to steam. Steam is provided from a boiler and is superheated by the fuel gas before being sent into the fluidized bed. The feed ratio between steam and biomass is relatively in the range of approximately 0.5 to 1.4. The vapor residence time is preferably about 2 to 4 seconds at a velocity of about 1 to 3 m/s.

Biomass is then introduced at the desired feed rate and the system is operated for gasification. The biomass is fed under a blanket of low pressure to the desired feed port and into the fluidized bed.

Pressure fluctuations in the pulse burner are preferably in the range from 1.4xl0<4> to 3.4xl9<4> (peak to peak). These pressure fluctuation levels are of the order of 165 to 190 dB in sound pressure level, resulting in 140 to 155 dB in radiated sound pressure outside the resonance tubes. The acoustic field that is radiated into the fluidized bed increases both heat and mass transfer in the fluidized bed itself and the reaction rate in the carburettor.

Results from the biomass gasification indicate that the reactor provides higher product quality and lower tar/char production levels than those achieved by others with reactor temperatures 56 to 83 K higher than the reactor and process temperatures in this example. The radiated acoustic field also increases the bed fluidization properties_and bubbling in the bed (growth of gas bubbles) is essentially eliminated. This affects species breakthrough in the bed and improves the reaction rate (steam utilization) and product quality. As a result of increased reaction rates, the process gives very high carbon conversion to product gas (97%) low char production (less than 3%), and apparently no tar (less than 12 ppm in the condensate). Due to the increased C2 -production, the total heating value of the product gas is high (about 20xl0<6> J/m* at 921 K) despite the relatively low methane concentration. In addition, about 0.20% of the dry product is acetylene (about 5% of the produced C2) •

The kinetics of acetylene formation is usually not favorable at 921 K. In reality, the biomass gasification process according to this example results in the formation of many high-temperature isomers. Acoustic stimulation in the gasifier is the reason for the increased reaction rates that cause such high temperature isomers to form at moderate reactor temperatures.

Example 2: Treatment of industrial and municipal waste

Steam gasification of energy-containing sludge waste streams of the type discharged from municipal waste treatment plants and industrial by-product waste is achieved by injecting the waste as sludge directly into the hot fluidized bed through a suitable injection port. Steam for the gasification reaction is provided by a boiler and is superheated by the fuel gas from the resonance tubes.

Results of the sludge waste gasification of fiber waste sludge containing plastics indicate high reaction rates due to the high rate of heat transfer into the fluidized bed and the increased heat and mass transfer rates induced in the fluidized bed by the presence of the acoustic field. The product result consisted of a medium energy gas with a calorific value greater than 15xl0<6> J/m* , and richer in hydrogen by approximately three to four times that obtainable with air driven direct gasifiers.

Example 3 Gasification of coal and peat

In another example, steam gasification and coal and peat are achieved by injecting material in slurry form, or dry form, directly into the hot bed fluidized by steam. Catalysts can be used as described for the steam reforming of heavy liquid hydrocarbons to activate the steam and increase the steam reforming and the gasification reactions of the charred mass.

The preferred fuels for steam gasification in this example are lignite and lignite

mixtures. The Lawerdi coal is directly injected into a hot fluidized bed of calcium aluminate and limestone that is held on

about 1032 to 1144 K, and up to 6.9xl0<5> Pa.

The devolatilization or non-volatilization of coal is carried out quickly due to the high heating rate and heat excess in the fluidized bed. Rapid devolatilization results in a highly porous and reactive charred mass. The steam/mass reaction takes place in the presence of calcium aluminate

and CaO and results in the formation of Co and H2. Depending on the particle size distribution of the fuel and the fluidization rate, the mass continues to react with the steam until it is washed out of the bed. The washed out charred mass is separated, for example in a separator. Preferably, dry sulfur carriers such as limestone having the appropriate particle size distribution are also injected into the bed to absorb sulfur. The wear and tear of the calcium-aluminate catalyst in the bed is very low and thus the costs due to leaching losses of the catalyst are low.

The solids (charred mass) limestone and some catalyst material which is separated in the separator are preferably fed to the pulse burner together with some product gas to provide the heat of reaction to the fluidized bed reactor. The size of the coal is chosen so that approximately 80% of the heat required for combustion is in the washed out charred pulp particles. The rest of the heat that is needed is obtained with the help of the product gas which is fed to the pulse burner together with washed out charred mass, ash and limestone. The limestone in the pulse burner will continue to

absorb sulfur released from the charred mass. The embodiment of the invention achieves 78% sulfur capture during the burning of coal with limestone in a pulse burner with a 1.5 to

1 calcium to sulfur ratio.

Example 4: Mild for<g>assin<g> of coal

In a further example, coal is pyrolysed

in a mild gasification process to produce useful fuel gases, liquids and solids. In this example, the reaction zone is filled with charred coal. Coal having a high volatile content, especially baking coal, is injected into the fluidized bed and pyrolyzed at a moderate temperature of about 921 K. The fluidized bed provides very rapid heating and devolatilization and produces a highly porous charred mass in the bed and product gases that include vapors of liquid hydrocarbons . The liquid substances can be further processed in a refinery to produce usable liquid fuels. The product gases are used to fluidize the bed by recirculation and provide carbon monoxide and hydrogen for the mild gasification

the process to improve the liquids' product quality. A small amount of steam is also added to the fluidizing medium to improve performance. The highly porous charred mass is then sold for use in coal-fired boilers. This example therefore has the purpose of producing synthetic gas and liquid fuels from suitable coal resources by mild reactor

condition and low capital costs.

Example 5: Cracking or splitting of chemicals and production

In a further example, tongues become liquefied

hydrocarbons and steam injected into a fluid bed reaction zone under controlled conditions to optimize

the production of high-value chemical products, such as ethylene, propylene and butylene. The preferred temperature range in the reaction zone is 1143 to 1254 K. The preferred pressure range is 1.4x10<5> to 2.1x10<5> Pa. The preferred fluid bed solids size is 600 nm.

In this example, liquid hydrocarbon fuel is atomized directly onto the hot bed particles comprising either an inert substrate or an acid catalyst. Direct contact between the hydrocarbon fuel and the hot particles or solid results in heating rates exceeding 1,000,000 L/second. Those skilled in the field of hydrocarbon cracking for the production of olefinic mixtures will understand that increased product performance is achieved by the high heating rate. Product gases from the reactor are rapidly cooled to prevent secondary coke formation reactions. The cooled product gases are then separated using conventional distillation devices to give valuable products such as ethylene, propylene, butylene, hydrogen and fuel gases.

In the currently used hydrocarbon cracking technology, hydrocarbon and water vapor are introduced into an indirectly heated tubular furnace reactor. Heat transfer from the pipe wall to the reactants is primarily convective. Because of the limited speeds with the reactants are primarily convective. Because of the limited rates of convective heat transfer that can be achieved in a tubular furnace reactor, the rate of reactant heating is also limited. This results in less than optimal performance of high value olefinic components.

In the example discussed here, the rate of reactant heating is not controlled by convective heat transfer mechanisms. Instead, direct contact and conduction between the liquid hydrocarbon and the hot solids gives extremely high heating rates. Furthermore, the hot solids, which have a typical diameter of 600 µm, will represent an enormous surface area for contact heat transfer. For example, the available surface area for heat transfer in a tubular furnace reactor is only 1 m<2> per cubic meter reactor furnace volume, while the available surface area in the exemplified fluidized bed reactor is 5000 m<2> per cubic meter reactor bed volume.

Under hydrocarbon cracking conditions necessary to produce high levels of olefinic mixtures, tubular furnaces are subject to high rates of coke deposition on the inner tube wall surfaces. This further limits the rate of heat transfer and increases the pipe wall temperature. For this reason, decoking of the pipe wall surface is carried out at regular intervals. Decoking involves the deposited carbon reacting with water vapor or air. The use of water vapor is desirable since the temperature in the decoking operation is controlled more easily than with air decoking, which is highly exothermic. However, steam decoking is a slower process that requires

longer periods when the plant is out of operation. In the exemplified fluidized bed embodiment, the coke deposit on the hot solids does not limit the heat transfer rate or the reactance heating. Any coke that forms on

the bed's heat transfer surface will be washed by the action of the fluidized bed solids. The problem with coke formation is thus less pronounced in the exemplified embodiment compared to tubular furnace reactors. If decoking is necessary in the exemplified fluid bed design, unnecessary overheating is also avoided due to the rich temperature distribution that characterizes the fluid bed.

Example 6: Recovery of oil from oil shale. tar sands and other oil-bearing minerals

In a further example, recycling of

crude oil from oil shale, tar sands and other oil or bitumen-containing minerals is carried out cost-effectively by producing large quantities of light, condensable hydrocarbons.

The preferred fuels in this version are oil shale and tar sands. In this example, appropriately sized oil shale is fed into the thermochemical reactor. The bed material is charred mass from previously retorted oil shale.

Small amounts of superheated steam and recycled product gas were used to fluidize the bed. The superheated steam enters the bed at 1061 to 1088 K.

The bed is kept at a working temperature of 810 to 866 K by indirect heating of the pulse burner. As the superheated steam enters the bed, the endothermic reaction between the charred mass and the steam will take place. This results in the production of primarily CO and hydrogen. The temperature of the steam is quickly reduced to the bed temperature due to the endothermic carbon steam reaction and the vigorous mixing in the fluidized bed. The pulse burner is fired with charred mass and some of the product gas. The combustion introduces oscillations which produce a turbulent flow in the resonance tubes. This increases the heat transfer from the walls of the resonance tubes to the fluidized bed. The overall heat transfer coefficient is as high as 283 W/m<2> K. The intense acoustic field radiated from the resonance tubes into the fluidized bed further increases both heat and mass transfer in the fluidized bed reactor, increasing both performance and H/ The C ratio in the product liquids. The high heat transfer rate and the acoustic field emitted by the pulse burner resonance tubes result in a rapid devolatilization and pyrolysis of the oil shale particles. The process thus reduces capital costs while achieving increased liquid product performance and quality. The indirectly heated continuous reactor system will also provide a highly porous and reactive carbonized mass with a low ash content, which is ideal for combustion applications.

Rapid heating (at rates above 10,000 K/second) and the presence of steam in the char bed generate nascent or incipient hydrogen and CO until the devolatilization of the oil shale particles. This results in the formation of reactive pyrolysis fragments or free radicals which are stabilized by nascent hydrogen as soon as they are formed. The fast devolatilization rate and the on-site availability of hydrogen increase the liquid yield with less tendency to polymerize. By preventing polymerization, it is possible to generate large quantities of easily condensable hydrocarbons.

The volatile products (consisting of condensable and non-condensable gases) leave the reactor after separation of the charred mass and other carriers in a separator. In common systems, the vapors are cooled with recirculation oil or hydrotreated recirculation oil. The non-condensable gases leave the cooling-washing tower for the removal of acid gases. The cooled condensable products will include pyrolysis water and light hydrogen oils and tars.

A portion is cooled and recycled back into the cooling washer.

The invention generally provides high heat and mass transfer rates in a well-controlled, low-temperature (lower than 600°C) reactor environment, short residence times, high heating times and a reactive steam atmosphere at low capital and operating costs.

Numbered examples

Example 1

Sodium carbonate was fluidized by a mixture of steam and smoke or combustion gas from a boiler and heated by heat transfer from a resonance tube under the following conditions: Starting temperature to

Temperature inside the pulse burner 1643-1920 K Temperature inside the resonance tube 1365-1920 K

Under stable operating conditions of the pulse burner and the fluidized bed, the temperature of the fluidized bed was maintained at 922 K. In this step, lye was injected into the sodium carbonate fluorinated bed. The lye underwent pyrolysis and gasification which produced solid, liquid and gaseous products. The solid product was deposited on the fluidized sodium carbonate and was withdrawn from the reactor. The vaporized liquid and gas products were withdrawn from the reactor and then cooled to separate condensed liquid products from the gas. The following results were obtained:

Analysis of lye, weight percent

Example 2

A mixture of sand and wood was fluidized by water vapor and heated by heat transfer from a resonant tube under the following conditions:

During stable operation of the pulse burner and the fluidized bed, the temperature of the fluidized bed was maintained at approximately 866 K. The wood underwent pyrolysis and steam gasification which produced solid, liquid and gaseous products. The reaction products were taken out of the reactor together with excess steam and then cooled. The following results were obtained:

Analysis of firewood, raw material weight percentage

Example 3

A sulfur-resistant reforming catalyst is fluidized by steam and heated by heat transfer from a resonance tube under the following conditions:

During steady state operation in the pulse burner and the fluidized bed, the temperature of the fluidized bed was maintained at approximately 1200 K. In this step, fuel oil is injected into the fluidized bed of the catalyst. The heating oil undergoes reforming by reaction with steam and produces synthesis gas and a heavy oil. The liquid and gas products are taken out of the reactor and then cooled to separate the condensed liquid from the gases. The following results are indicated:

Analysis of fuel oil, weight percent

Example 4

A mixture of limestone and waste sludge from a paper mill was fluidized by steam and heated directly by heat transfer from a resonance tube under the following conditions: Starting temperature for calcium carbonate

Under stable operating conditions in the pulse burner and the fluidized bed, the temperature of the fluidized bed was maintained at 949 K. The sludge underwent steam gasification which gave solid, liquid and gas products. The following results were obtained:

Example 5

Subbituminous coal is fluidized by steam and heated by heat transfer from a resonance tube under the following conditions:

Under stable operating conditions for the pulse burner and the fluidized bed, the temperature of the fluidized bed was kept at 885 K. The coal undergoes pyrolysis and gasification, which gives solid, liquid and gas products. The products from the coal are taken out of the reactor together with excess steam and then cooled to separate the water. In the following results are indicated:

Typical analysis of coal, weight percent

Example 6

Oil shale is fluidized by fuel gas from an oil-fired pulse burner and heated by heat transfer from a resonance tube under the following conditions:

During stable operating conditions in the pulse burner and the fluidized bed, the temperature of the fluidized bed was kept at 921 K. Oil shale that feeds the reactor undergoes pyrolysis and gives liquid and gas products. The products from the oil shale are taken out of the reactor and then cooled to separate liquid products. The following results are indicated:

Claims (3)

1. Method for converting carbonaceous material into product gas by heating a fluidized bed, characterized in that a combustion chamber is used to provide the heat, the method comprising: (a) introducing a fuel, for example including charred biomass and an oxygen-containing gas into in a pulse-burning zone; (b) combustion of at least part of said fuel which is introduced into said pulse combustion zone under conditions to effect pulse combustion of said at least one part of said fuel and thereby produce a hot gas stream comprising the remaining part of said fuel and a acoustic pressure wave; wherein said pulse combustion is operated, for example, to produce velocity oscillations in the range from about 30 to 1500 Hz, and an acoustic pressure level in a reaction zone in the range from about 110 to 190 dB; (c) withdrawing said hot gas flow from said pulse combustion zone into an inlet to a resonance zone delimited by a conductor wall, where said resonance zone has said inlet at one end and an outlet at the other end and is surrounded by a layer of solid particles, and said particles are of a size such that they can be induced into agitated motion by a flow of steam through the bed and are confined in said reaction zone surrounding said resonance zone; (d) burning at least a portion of said remaining portion of said fuel in said hot gas stream in said resonance zone to thereby produce a combustion product stream; (e) flowing steam through said reaction zone at a rate suitable to maintain said massive particles in an agitated "state; (f) heating said bed of solid particles in said reaction zone by heat transfer from said combustion product stream in said resonance zone and through said conductor wall to said layer of solid particles, thereby defining a total rate of heat transfer from said combustion product flow to said layer of solid <p>particles which is at least twice as high as what could be achieved by burning said fuel in said combustion -zones in the absence of pulse combustion; the heat transfer being, for example, such that it maintains the reaction zone at a temperature of 510 to 870°C, (g) allowing said acoustic pressure wave from said pulse combustion zone to propagate into said reaction zone containing said layer of solid particles; and (h) introducing a carbonaceous material, for example biomass into said rea tion zone with said solid particles in said layer while said solid particles are in said agitated state, thereby causing said carbonaceous material to undergo an endothermic chemical reaction with said steam to produce said product gas with a calorific value of 17.7 to 21.4 MJ /m<3> (475 to 575 Btu/ft<3>). 2. Method of using a heated fluidized bed to recover the energy and chemical content of black liquor without producing a melt, where indirect heat is used to heat the bed, and the method comprises the following steps: (a) providing a bed of solid sodium salts, for example sodium carbonate, in a reaction vessel; (b) injecting steam into said bed to maintain said bed in an agitated state, for example at a rate capable of producing a velocity in the range of 0.3 to 3 m/s in said bed, characterized by (c) indirect heating of said agitated bed to a substantially uniform temperature in the range from 510 to 730°C (for example 590 to 680°C) by heat transfer from combustion tubes immersed in said layer, and said combustion tubes comprise, for example, one or several resonance tubes for one or more pulsating burners; (d) spraying black liquor directly onto the hot bed material; (e) allowing said black liquor to react with said steam in said bed to form product gas containing hydrogen sulphide; (f) withdrawing said product gas from said reactor and (g) washing said product gas with a sodium carbonate solution to form green liquor and purified <p>product gas, said purified product gas having, for example, a heating value in the range of 9.3 to 16.8 MJ/m<3> (250 to 450 Btu/ft3K 3. Fluidized bed apparatus for recovering the energy and chemical content of black liquor without producing a melt, where indirect heat is provided to heat the fluidized bed, characterized in that the apparatus comprises: (a) a reaction container containing a layer of solid sodium carbonate and an outlet for extracting product gas from said container; (b) a steam injection device for introducing steam into said reactor and operable to maintain said bed in an agitated state at a surface velocity of from 0.9 to 2.1 m/s. (c) a heat transfer device for indirectly heating said agitated layer to a uniform temperature in the range from 510 to 700°C, said heat transfer device comprising one or more fire tubes immersed in said layer, and said heat fire tubes for example comprising resonance tubes for one or more pulse burners; (d) a feeding device for introducing black liquor into said agitated bed in said reaction vessel; (e) a device for extracting product gas from said reactor; and (f) a washing device for washing hydrogen sulphide from said product gas to form green liquor and purified product gas. <*>• Process for steam reforming of heavy, liquid hydrocarbons in two stages, characterized by the use of a first-stage reactor with a fluidized bed and a second-stage reactor with. fixed bed, the method comprising the following steps: (a) providing a bed of a solid steam-activating and carbon gasification-promoting catalyst in a first reaction vessel; (b) injecting steam into said bed to maintain said bed in an agitated state; (c) indirectly heating said agitated bed to a substantially uniform temperature by heat transfer from fire tubes immersed in said bed; and said fire tube, for example, comprises one or more resonant tubes in one or more pulsating burners; (d) spraying said heavy liquid hydrocarbons directly onto the hot bed solid so that said heavy liquid hydrocarbons react with said steam in said catalyst bed to form a partially reformed gas containing hydrogen, light hydrocarbons and hydrogen sulphide; (e) extracting said partially reformed gas from said first reaction vessel; and (g) steam reforming said partially reformed gas in a second reaction vessel containing a retained bed of a solid catalyst heated to a substantially uniform temperature in the range of 900 to 980°C by heat transfer from fire tubes immersed in said bed to produce an end product gas. 5. Two-stage apparatus for steam reforming of heavy liquid hydrocarbons, where a first-stage reactor with a fluidized bed and a second-stage reactor with a fixed bed are used, characterized in that it comprises: (a) a first reaction vessel comprising a bed of a solid, then-activating and carbon gasification-promoting catalyst; (b) a steam injection device for introducing steam into said first reactor and operable to maintain said bed in an agitated state; (c) a heat transfer device for indirect heating of said agitated layer, where said heat transfer device comprises one or more fire tubes immersed in said layer, and said fire tubes comprise, for example, one or more resonant tubes in one or more pulsating burners; (d) a feed device for spraying heavy liquid hydrocarbons onto said agitated bed solids in said first reaction vessel; (e) a device for extracting partially reformed gas from said first reactor; and (f) a second reactor means for steam reforming said partially reformed gas to form an end product gas; in that said second reactor device contains a retained layer of a solid catalyst heated to an essentially uniform temperature in the range from 900 to 980°C by heat transfer from fire tubes immersed in said layer.