US20010027737A1 - Gasifier system and method - Google Patents

Gasifier system and method Download PDF

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Publication number
US20010027737A1
US20010027737A1 US09/138,020 US13802098A US2001027737A1 US 20010027737 A1 US20010027737 A1 US 20010027737A1 US 13802098 A US13802098 A US 13802098A US 2001027737 A1 US2001027737 A1 US 2001027737A1
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Prior art keywords
air
fuel
boiler
solid fuel
firebelt
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Abandoned
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US09/138,020
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English (en)
Inventor
Stan E. Abrams
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Nathaniel Energy Corp
Original Assignee
NATHANIEL Ltd
ROBINSON ENVIRONMENTAL Corp
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Application filed by NATHANIEL Ltd, ROBINSON ENVIRONMENTAL Corp filed Critical NATHANIEL Ltd
Priority to US09/138,020 priority Critical patent/US20010027737A1/en
Assigned to ROBINSON ENVIRONMENTAL CORPORATION, NATHANIEL, LTD. reassignment ROBINSON ENVIRONMENTAL CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ABRAMS, STAN E.
Priority to DE69943109T priority patent/DE69943109D1/de
Priority to EP99940818A priority patent/EP1112460B1/de
Priority to PCT/US1999/016728 priority patent/WO2000011402A1/en
Priority to AT99940818T priority patent/ATE494512T1/de
Publication of US20010027737A1 publication Critical patent/US20010027737A1/en
Priority to US10/061,362 priority patent/US6532879B2/en
Assigned to NATHANIEL ENERGY CORPORATION reassignment NATHANIEL ENERGY CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ABRAMS, STAN E.
Assigned to ALTERNATE POWER, INC. reassignment ALTERNATE POWER, INC. SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: NATHANIEL ENERGY CORPORATION
Priority to US10/331,559 priority patent/US6959654B2/en
Priority to US10/812,393 priority patent/US7007616B2/en
Abandoned legal-status Critical Current

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G5/00—Incineration of waste; Incinerator constructions; Details, accessories or control therefor
    • F23G5/02—Incineration of waste; Incinerator constructions; Details, accessories or control therefor with pretreatment
    • F23G5/027—Incineration of waste; Incinerator constructions; Details, accessories or control therefor with pretreatment pyrolising or gasifying stage
    • F23G5/0276—Incineration of waste; Incinerator constructions; Details, accessories or control therefor with pretreatment pyrolising or gasifying stage using direct heating
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G5/00—Incineration of waste; Incinerator constructions; Details, accessories or control therefor
    • F23G5/006—General arrangement of incineration plant, e.g. flow sheets
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G5/00—Incineration of waste; Incinerator constructions; Details, accessories or control therefor
    • F23G5/08—Incineration of waste; Incinerator constructions; Details, accessories or control therefor having supplementary heating
    • F23G5/14—Incineration of waste; Incinerator constructions; Details, accessories or control therefor having supplementary heating including secondary combustion
    • F23G5/16—Incineration of waste; Incinerator constructions; Details, accessories or control therefor having supplementary heating including secondary combustion in a separate combustion chamber
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G5/00—Incineration of waste; Incinerator constructions; Details, accessories or control therefor
    • F23G5/44—Details; Accessories
    • F23G5/442—Waste feed arrangements
    • F23G5/444—Waste feed arrangements for solid waste
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23L—SUPPLYING AIR OR NON-COMBUSTIBLE LIQUIDS OR GASES TO COMBUSTION APPARATUS IN GENERAL ; VALVES OR DAMPERS SPECIALLY ADAPTED FOR CONTROLLING AIR SUPPLY OR DRAUGHT IN COMBUSTION APPARATUS; INDUCING DRAUGHT IN COMBUSTION APPARATUS; TOPS FOR CHIMNEYS OR VENTILATING SHAFTS; TERMINALS FOR FLUES
    • F23L15/00—Heating of air supplied for combustion
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G2201/00—Pretreatment
    • F23G2201/30—Pyrolysing
    • F23G2201/303—Burning pyrogases
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G2203/00—Furnace arrangements
    • F23G2203/105—Furnace arrangements with endless chain or travelling grate
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G2203/00—Furnace arrangements
    • F23G2203/80—Furnaces with other means for moving the waste through the combustion zone
    • F23G2203/801—Furnaces with other means for moving the waste through the combustion zone using conveyors
    • F23G2203/8016—Belt conveyors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G2205/00—Waste feed arrangements
    • F23G2205/12—Waste feed arrangements using conveyors
    • F23G2205/122—Belt conveyor
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G2205/00—Waste feed arrangements
    • F23G2205/18—Waste feed arrangements using airlock systems
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G2206/00—Waste heat recuperation
    • F23G2206/20—Waste heat recuperation using the heat in association with another installation
    • F23G2206/203—Waste heat recuperation using the heat in association with another installation with a power/heat generating installation
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G2900/00—Special features of, or arrangements for incinerators
    • F23G2900/50006—Combustion chamber walls reflecting radiant energy within the chamber
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23J—REMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
    • F23J2217/00—Intercepting solids
    • F23J2217/40—Intercepting solids by cyclones
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23J—REMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
    • F23J2217/00—Intercepting solids
    • F23J2217/50—Intercepting solids by cleaning fluids (washers or scrubbers)
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N1/00—Regulating fuel supply
    • F23N1/02—Regulating fuel supply conjointly with air supply
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N2223/00—Signal processing; Details thereof
    • F23N2223/02—Multiplex transmission
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N2223/00—Signal processing; Details thereof
    • F23N2223/08—Microprocessor; Microcomputer
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N2237/00—Controlling
    • F23N2237/16—Controlling secondary air
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N5/00—Systems for controlling combustion
    • F23N5/003—Systems for controlling combustion using detectors sensitive to combustion gas properties
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E20/00—Combustion technologies with mitigation potential
    • Y02E20/12—Heat utilisation in combustion or incineration of waste
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E20/00—Combustion technologies with mitigation potential
    • Y02E20/34—Indirect CO2mitigation, i.e. by acting on non CO2directly related matters of the process, e.g. pre-heating or heat recovery

Definitions

  • This invention relates to gasifier systems and methods for the efficient conversion of solid fuels to usable heat energy.
  • the burner utilizes a first burning chamber having a falling fuel entrained bed zone positioned above a traveling grate having a porous metallic woven belt. Primary air is directed through the porous belt to establish an oxygen-starved first burning chamber. A second burning chamber in fluid communication with the first burning chamber has a restricted diameter and effectively provides a hot-air gas nozzle.
  • a plurality of conveyors constitutes the traveling grate with the conveyors being arranged in head-to-head stepped relationship so that unburned fuel received by gravity from the entrained bed zone is agitated or jostled to enhance its burning.
  • firebelts ensure that the heat loss from heating unnecessary air is minimized.
  • the quantity of air at each point in the combustion process is stringently controlled. This air control benefits the combustion process in three ways:
  • nitrogen oxides another priority pollutant, is produced by combining the nitrogen in the air with the oxygen in the air. This combination of nitrogen and oxygen only occurs at high temperatures. The higher the temperature, the greater the quantity of nitrogen oxides that are produced. While the combustor of the present invention utilizes high temperatures, the formation of nitrogen and oxides is minimized since there is no excess oxygen to combine with the nitrogen. All the oxygen is used in the combustion process.
  • a further feature of the present invention is in the use of reflected infrared energy.
  • Heat is a form of electromagnetic energy similar to light where the rays can be refracted or reflected. Radiation produced from heat is of a longer wavelength than visible light and is called infrared rays.
  • This invention is able to supply heat to the gasification process. The reflected heat will be of benefit in two ways:
  • the heat is reflected to a point where the heat can be used to assist the combustion process. This is generally where the fuel first enters the combustion process. At this point, the fuel must be heated and the water removed. These processes require addition of energy which can be added for heat of the combustion of a part of the fuel or from the reflected energy. Using a part of the fuel to preheat the remaining fuel is inefficient, leaving less total heat available for production of electricity. Using reflected heat removes or minimizes this inefficiency. The second way this benefits the overall combustion process is in that the energy is transferred in a beneficial way—not wasted by irradiating and heating in the combustion chamber. Heat that is absorbed by the combustion chamber is generally wasted since there is no direct benefit from this radiation.
  • Another feature of the invention is that the speed of the conveyor drive and the rate of inlet air and the control of inlet air is much more closely controlled so as to achieve high efficiency. Still another feature of the invention is that the fuel feed ramping is based on thermal conditions at the boiler output.
  • Still another feature of the invention is that the induced draft fan control is based on the draft pressure and boiler airflow rate.
  • Still another feature of the invention is in the method to control catalyst feed levels based on pollutant levels in the stack as measured at a continuous emission monitoring system point.
  • the invention features a control system which is based on operational parameters sensed at different stages in the process.
  • the object of the invention is to provide an improved gasifier system.
  • FIG. 1 is a diagrammatic sectional illustration of a gasifier system incorporating the invention
  • FIG. 2 is a cross-sectional illustration of a walking floor trailer and inclined conveyor incorporated in the invention for feeding fuel to the combustor unit,
  • FIG. 3 is a diagrammatic illustration, of the bin feeder and rotary air lock incorporated in the invention
  • FIG. 4 is a diagrammatic illustration of the boiler for converting thermal energy to steam
  • FIG. 5 is a diagrammatic illustration of the cyclone and baghouse particulate collection division
  • FIG. 6 is a diagrammatic illustration of the scrubber for removing acid gases from the exhaust gas stream
  • FIGS. 7A, 7B and 7 C are flow diagrams illustrating the combustion process and location of various sensors and control elements incorporated in the invention.
  • the gasifier system comprises an inlet feed conveyor and fuel metering unit 10 , a gasifier 11 , a gasifier firetube with connection to boiler 12 , the boiler itself 13 , a cyclone 14 , baghouse 15 , scrubber 16 , and control system 17 which control system is diagrammatically illustrated in FIGS. 7A, 7B and 7 C.
  • This section delivers the prepared fuel to the gasifier. It includes the bin conveyor and rotary airlock.
  • the control system determines the required fuel flow for proper gasification and the quantity to sustain the output of steam from the boiler. It then determines the required speed of the conveyor and the airlock.
  • the walking floor trailer 2 - 10 is used to store and deliver fuel to the combustor with the inclined conveyor.
  • the bin conveyor 2 - 12 monitors the amount of fuel and calls for additional fuel from the walking floor trailer when necessary.
  • the walking floor trailer 2 - 10 works in the following manner:
  • the floor 2 - 14 is comprised of a number of strips that independently move. To move the fuel to the rear of the trailer (left end in FIG. 2), the strips all move together rearward. At the end of the cycle (approximately four inches), each strip independently moves forward, leaving the fuel undisturbed. This cycle is repeated as required to move the fuel rearward as much as necessary.
  • a monitor or sensor 2 - 15 is located at the input end of inclined conveyor 2 - 11 .
  • the inclined conveyor 2 - 11 monitors the quantity of fuel located at the end of the trailer (the beginning of the inclined conveyor) and moves the fuel rearward in the walking floor trailer as required to maintain sufficient fuel in the inclined conveyor.
  • the bin feeder receives the fuel from the inclined elevator 2 - 11 (FIG. 2).
  • the bin feeder is used to meter the fuel to the combustor.
  • the bin feeder 3 - 11 speed will be varied to introduce sufficient fuel to the combustor.
  • a sensor 3 - 10 is used on the bin feeder to ensure that sufficient fuel is present on the bin feeder belt. If additional fuel is needed, a signal is sent to the inclined conveyor/walking floor trailer (FIG. 2) for additional fuel.
  • the rotary air lock 3 - 12 is used to provide a mechanical seal to minimize the quantity of unwanted air introduced into the combustor.
  • stage 1 The area of this gasification is referred to as stage 1.
  • the gasification in this stage is controlled totally by the control system by taking the following parameters and the system computer determines the variables that need to change or remain the same during the gasification process:
  • variable control of air through the firebelts (conveyors) 20 , 21 is the primary reason for the extremely low air emissions from the combustor disclosed herein. Controlling the amount of air that passes through each unit area of the firebelts governs the quantity and quality of the combustion process.
  • the combustion process requires two components; fuel and an oxidizer. Normally, air is used as an oxidizer but air contains many gases, most of which do not contribute to the oxidation process. In fact, the other gases in air can have a deleterious effect on the overall combustion efficiency.
  • the quantity of air at each point of the combustion process is stringently controlled. This air control benefits the combustion process in three ways.
  • the first way is by minimizing the heat loss in the combustion process. This minimizes the amount of carbon monoxide produced. Carbon monoxide, a priority pollutant, is produced directly proportional to the combustion temperature. Therefore, by minimizing excess air we minimize the quantity of carbon monoxide.
  • nitrogen oxides another priority pollutant, is produced by combining the nitrogen in air with the oxygen in the air. This combination of nitrogen and oxygen only occurs at high temperatures. The higher the temperature, the greater the quantity of nitrogen oxides that is produced. While the combustor disclosed herein utilizes very high temperatures, the formation of nitrogen oxides is minimized since there is no excess oxygen to combine with the nitrogen. All of the oxygen is used in the combustion process.
  • Heat reflection is another innovative feature of the combustor of this invention.
  • Heat is a form of electromagnetic energy, similar to light where the rays can be refracted or reflected. Radiation produced from heat is of a longer wavelength than visible light and is called infrared rays.
  • the first way is that by the heat reflected to a point where the heat can be used to assist the combustion process. This is generally where the fuel first enters the combustion process. At this point, the fuel must be heated and the water removed. These processes require the addition of energy which can be added from either the combustion of a part of the fuel or from the reflected energy. Using a part of the fuel to preheat the remaining fuel is inefficient, leaving less total heat available for the production of electricity. Using the reflected heat removes or minimizes this inefficiency.
  • the second way reflected heat benefits the overall combustion process is that the energy is transferred in a beneficial way and is not wasted by irradiating and heating the combustion chamber. Heat that is absorbed by the combustion chamber is generally wasted since there is no direct benefit from this radiation. A small portion is used in the maintenance of the necessary combustion temperature, but the majority of the radiative heat is wasted as low level heat radiated from the combustor exterior. The reflection of the heat back onto the fuel will benefit the overall combustion efficiency.
  • stage 2 This is actually a part of the gasifier and is referred to as stage 2. It is the connecting tube to the boiler 13 . Outside ambient air is preheated between outer skins of the gasifier and injected at a rate controlled by the control system. When this oxygen rich air meets the gas from the gasifier, ignition takes place in the firetube and thus enters the boiler. The following parameters are taken in the firetube for the control system's use:
  • Boiler 13 See FIG. 7B
  • the boiler 13 (FIG. 4) converts the thermal energy to steam.
  • the following parameters are taken in the boiler for the control system use for control of the feed rate and the steam output:
  • the boiler 4 - 10 ( 13 ) used in this embodiment of the invention is of the Scotch Marine Type of boiler.
  • Other types of boilers such as A-frame, H-frame may be used in other installations.
  • the boiler 4 - 10 absorbs the heat produced from the combustion of the fuel and transfers it to water, which is converted into steam.
  • the steam is used to produce mechanical work such as electrical generation, heating, etc.
  • the Scotch Marine Boiler is a three-pass type of boiler.
  • the first pass is through a large diameter central tube 4 - 11 .
  • Approximately 40% of the usable heat is absorbed during the first pass. This heat is used to heat the water and to convert part of the water into steam.
  • the second pass is in the reverse direction through a series of small tubes 4 - 12 .
  • An additional 40% of the usable heat is absorbed during the second pass.
  • the remaining water is converted into steam by the heat absorbed during the second pass.
  • the third pass is again through a large diameter tube 4 - 14 where the remaining 20% of the heat is absorbed. This heat is used to, in essence, superheat the steam and ensure that no liquid water remains.
  • An economizer may be attached after the boiler to preheat the water and improve efficiency. This is not shown in this embodiment.
  • the cyclone 14 (FIG. 5) is the first mechanical device that removes particulate.
  • the design of the cyclone is such that when the air flows through it from the boiler the largest particulate will drop from the airflow through the bottom of the cyclone to a storage container.
  • the following parameters are measured (see FIG. 7B) for the control system 17 in the cyclone:
  • the cyclone 5 - 10 and baghouse 5 - 11 operate as particulate collection devices. In the combustion process, as the fuel is combusted a small percentage of ash remains. Some of this ash is entrained within the combustion air stream and is carried along with the exhaust gases, called fly-ash. The cyclone 5 - 10 and baghouse 5 - 11 remove the fly-ash so that it is not emitted into the atmosphere.
  • the cycle acts through centripetal action.
  • the gas spins around in the cyclone and separates the heavy particles from the gas based upon weight.
  • the ash particles are collected at the bottom of the cyclone and removed through a rotary air lock and a vacuum removal system (eductor).
  • the baghouse operates on a different principle.
  • the gas passes through a series of fiberglass bags 5 - 13 that have very small openings within them.
  • the gas can pass through but the particles cannot and remain adsorbed to the exterior of the bag.
  • high-pressure air is introduced inside the bags. This air literally forces the particles off of the bags and they fall to the bottom of the baghouse.
  • the particles then are collected through a rotary air lock and an eduction system similar to the cyclone.
  • the baghouse 15 (FIG. 5) is the final removal equipment for particulate.
  • the mesh size of the bags will be determined by the particulate discharge requirements. The following parameters are taken in the baghouse for the control system use:
  • the scrubber 6 - 10 is used to remove acid gases from the exhaust gas stream.
  • a mixture of lime (calcium oxide, a strong caustic) and water is sprayed 6 - 11 through the exhaust gas.
  • This liquid chemically reacts with the acid gases such as sulfur dioxide, hydrogen chloride, etc. to remove the acid gases.
  • Plastic or ceramic open-frame balls are often used as packing to increase the surface area of the contact surface to improve the efficiency of the chemical reaction.
  • demisters 6 - 13 to remove all excess liquid. The gas then proceeds to the stack exhaust fan where the clean exhaust gas is vented to the atmosphere.
  • the scrubber 6 - 10 (FIG. 6) cleans the bad gases from the air stream before discharge to the atmosphere. It is usually a wet or dry lime injection system depending on the discharge requirements. The following parameters are taken for the control system that then determines the feed rate for the catalytic agent:
  • the control system (see flow charts in FIGS. 7A, 7B and 7 C) is the determining factor for the gasification system to operate properly and to be in compliance with the regulatory requirements for air discharge. It includes Programmable Logic Controllers (PLC's) and variable speed drives, diagrammatically illustrated in FIGS. 7A, 7B and 7 C, that operate the various motors, fans and drives that operate the gasifier system.
  • PLC'S are in turn controlled by signals from a computer that is programmed to recognize all the variables listed plus other minor items and to react properly from the data base.
  • the program is designed to make adjustments for different types of fuels (with different BTU content) without changing equipment in the gasifier system.
  • the release of chemical potential energy is a two-stage process: Stage 1 gasifies the carbon-based solid fuels and Stage 2 oxidizes the gasified fuels to produce heat.
  • Stage 1 is subdivided into two separate processes involved in the gasification of solid fuels.
  • Stage 1a uses thermal decomposition of the solid fuel introduced into the combustor to break the fuel into gaseous fractions of lower molecular weight or elemental composition. All absorbed compounds in the fuel such as water and other solvents are released in this stage.
  • a polymerized hydrocarbon based fuel (both plastic and lignin/cellulose base fuel) is decomposed into short chain aliphatic hydrocarbons, elemental carbon, carbon monoxide and hydrogen through the addition of energy as heat.
  • Other elemental based polymers including sulfur and silicon based compounds are similarly broken into appropriate monomers or elements using the same process.
  • the ash produced from Stage 1a is largely carbon with small amounts of metal oxides.
  • the heat required for the endothermic decomposition of the fuel is produced from heat supplied from stage 1b and from limited oxidation of fuel in stage 1a.
  • the oxidation of the solid fuel is limited in this stage by careful control of air added to the combustion process in Stage 1a.
  • the amount of air injected into Stage 1a is controlled by the amount of oxidation required to maintain the minimum necessary decomposition temperature in this stage.
  • Stage 1b utilizes an exothermic partial oxidation of the carbon in the ash to produce carbon monoxide and heat.
  • the remaining solid ash consists entirely of metallic oxides.
  • the reaction in Stage 1b is limited to partial oxidation of the carbon by controlling the air injected into Stage 1b.
  • Solid fuel is introduced to the combustor section 1a (firebelt 20 ) where gasification and moisture removal occurs.
  • a minimal amount of air is introduced to Section 1a to maintain the minimum gasification temperature necessary for the specific type of fuel used.
  • Radiative energy from Section 1b, firebelt 21 also added to the energy required for gasification.
  • the gases exiting this section consist of primarily carbon monoxide, hydrocarbons (short-chain and long-chain) and water vapor with minimal quantities of carbon dioxide and the balance of nitrogen.
  • the ash produced through the gasification process consists of carbon, long-chain, high-boiling-point hydrocarbons and metallic oxides.
  • Control of the gasification process is accomplished by modulation of the fuel feed rate, the quantity of air introduced through firebelts as measured by the oxygen concentration, the gasification temperature and the speed of the firebelts. Air injected into the solid fuel is minimized to prevent quenching of the air/fuel reaction and to prevent complete oxidation of carbon to carbon dioxide. The firebelt speed is controlled so that the solid fuel has been completely gasified at the end of the belt.
  • the carbon ash from firebelt 20 falls onto section 1b (firebelt 21 ) where additional air, in decreasing quantities, is supplied to combust the carbon to carbon monoxide as well as decomposition of the long-chain hydrocarbons to carbon monoxide and hydrogen.
  • Section 1b gases consist of carbon monoxide (10-15%), hydrogen (5-20%) and carbon dioxide (1-10%) with the balance of the gas being nitrogen.
  • the ash remaining from this process consists of metallic oxides with trace quantities of carbon-based compounds. Oxygen content is minimized in stage 1b to prevent oxidation of the carbon to carbon dioxide.
  • the firebelt speed is controlled to ensure complete oxidation of the ash just before the end of the belt.
  • stage 1b Radiative energy produced from stage 1b is reflected off of the refractory walls onto section 1a where it is used to gasify the solid fuel.
  • Control of the section 1b process is performed by the firebelt 21 speed, stage 1b temperature, control of the air to fuel ratio through firebelt 21 as measured by the oxygen concentration and by the overall draft (negative pressure) of the combustor system.
  • Stage 2 combustion occurs within the firetube and within the boiler where the carbon monoxide and hydrogen gases are oxidized to carbon dioxide and water by the addition of additional air.
  • the firetube is used for mixing of the air and fuel gas with final combustion occurring within the boiler cavity.
  • the Stage 2 combustion process is controlled by the air/fuel gas ratio, boiler temperature, firetube temperature, carbon monoxide concentration, oxygen concentration, carbon dioxide concentration and by the overall draft of the combustor system.
  • the combustor of the invention is a remarkably simple combustion system, and it is very easy to minimize the air pollutants that are produced from the combustion of solid fuels. This is not the case with other combustor systems currently on the market. With two exceptions, the combustor disclosed herein is the only combustion system that does not require a gaseous fuel afterburner to remove excess pollutants. The remaining two combustion systems are on the order of ten times as expensive to accomplish the same degree of pollution control as the combustor of this invention.
  • Particulates are released into the atmosphere from materials in the fuel which cannot be burned. Usually these particles are a chemical part of the fuel and when burned, recombine as small particles. Part of these particles agglomerate together in chunks which then collect in the bottom of the combustor and are removed as bottom ash. The remaining particles are carried in the flue gas.
  • Sulfur oxides are produced by the nitrogen combining with oxygen in the presence of high temperatures. Generally, the higher the temperature, the higher the quantity of nitrogen oxides produced. Because nitrogen oxides have been found to be a contributing factor in the destruction of ozone in the atmosphere, the emission of these compounds are regulated and must be minimized.
  • the present combustor uses a different method to reduce nitrogen oxides. By closely controlling the amount of air that is introduced into the combustion process, the formation of nitrogen oxides is minimized. Nitrogen oxides cannot form if there is not oxygen to combine with the nitrogen. In the combustion process disclosed herein, only enough air is added to the fuel to perform the necessary combustion of the fuel. Because there is no additional oxygen, there are very low quantities of nitrogen oxides produced. Excess air is added only at the very end of the combustion process to ensure complete combustion of the fuel. Using this process, very low concentrations of nitrogen oxides are emitted into the atmosphere.
  • Carbon Monoxide is the result of incomplete combustion. This is due to either low combustion temperatures or insufficient combustion air. In the combustor of this invention, the combustion temperature exceeds 3,000° F. for all solid fuels and 4,000° F. using tires. To ensure that the combustion process is complete and no carbon monoxide remains, a small amount of excess air is added to the final stage of combustion. This results in low concentrations of carbon monoxide and low concentrations of nitrogen oxides, a feat unable to be accomplished by any other combustor without an afterburner or a catalytic converter.
  • Volatile hydrocarbons or volatile organic carbons are a class of compounds that are regulated by the Environmental Protection Agency. These compounds include a wide range of chemicals that can be emitted into the atmosphere. Included in this list are compounds like dioxins, polychlorinated biphenyls (PCBs), polynuclear aromatics (PNAs) and other hazardous air pollutants (HAPs).
  • PCBs polychlorinated biphenyls
  • PNAs polynuclear aromatics
  • HAPs hazardous air pollutants
  • CEMS Continuous Emission Monitoring System
  • Some of the parameters that are monitored include:
  • the monitoring system continuously records the rate at which the pollutants are released into the atmosphere. These records must be submitted to the regulators to prove that the facility did indeed meet the required standards.
  • the combustion control process is a series of nested control loops that provide the necessary regulation of heat production.
  • the primary loop that controls the heat production is regulated by the quantity of fuel that is admitted to the combustor.
  • the fuel feed must have a wide range of quantities due to the variety of fuels used in the combustor.
  • combustion control loops that regulate the combustion process in Stages 1a, 1b and Stage 2. This is controlled by the speed of the combustion belts and the quantity of air added to the fuel as it is combusted. The goal of these control loops is to have the fuel completely consumed while maintaining the required pollution control.
  • All of the components controlled in the combustion system contain feedback to inform the control system if a component malfunctions.
  • Different component types use different types of feedback; for example, the air control dampers include a position sensor so that the damper position set by the controller is returned to the controller. If the position of the damper differs from the setpoint, the operator is informed and if the error is beyond a certain limit, the combustor is shut down.
  • control system is designed so that minor component malfunctions are either self-corrected or the programming compensates for the error. If minor errors are noted by the control system, the system operator and system maintenance personnel are notified for repair or replacement. This gives the control system a great deal of intelligence including, where possible, predictive failures.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Environmental & Geological Engineering (AREA)
  • Organic Low-Molecular-Weight Compounds And Preparation Thereof (AREA)
US09/138,020 1998-08-21 1998-08-21 Gasifier system and method Abandoned US20010027737A1 (en)

Priority Applications (8)

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US09/138,020 US20010027737A1 (en) 1998-08-21 1998-08-21 Gasifier system and method
DE69943109T DE69943109D1 (de) 1998-08-21 1999-08-20 Vergasungssystem
EP99940818A EP1112460B1 (de) 1998-08-21 1999-08-20 Vergasungssystem
PCT/US1999/016728 WO2000011402A1 (en) 1998-08-21 1999-08-20 Gasification system and method
AT99940818T ATE494512T1 (de) 1998-08-21 1999-08-20 Vergasungssystem
US10/061,362 US6532879B2 (en) 1998-08-21 2002-02-04 Gasifier system and method
US10/331,559 US6959654B2 (en) 1998-08-21 2002-12-31 Gasifier system and method
US10/812,393 US7007616B2 (en) 1998-08-21 2004-03-30 Oxygen-based biomass combustion system and method

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US09/138,020 US20010027737A1 (en) 1998-08-21 1998-08-21 Gasifier system and method

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US10/061,362 Division US6532879B2 (en) 1998-08-21 2002-02-04 Gasifier system and method
US10/812,393 Continuation-In-Part US7007616B2 (en) 1998-08-21 2004-03-30 Oxygen-based biomass combustion system and method

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CN103868368A (zh) * 2014-04-03 2014-06-18 贵研资源（易门）有限公司 等离子炉熔炼富集贵金属过程中尾气净化的方法
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CN113218233A (zh) * 2021-04-06 2021-08-06 关学忠 一种加热炉火管清垢防垢方法及防垢装置
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US20100193743A1 (en) * 2007-09-25 2010-08-05 Refgas Limited Gasification
US8801904B2 (en) * 2012-07-03 2014-08-12 Aemerge, LLC Chain drag system for treatment of carbaneous waste feedstock and method for the use thereof
US9795940B2 (en) 2012-07-03 2017-10-24 Aemerge, LLC Chain drag system for treatment of carbaneous waste feedstock and method for the use thereof
CN103868369A (zh) * 2014-04-03 2014-06-18 贵研资源（易门）有限公司 等离子炉熔炼富集贵金属过程中的尾气净化装置
CN103868368A (zh) * 2014-04-03 2014-06-18 贵研资源（易门）有限公司 等离子炉熔炼富集贵金属过程中尾气净化的方法
US11879639B2 (en) * 2019-12-19 2024-01-23 Raymond Dueck Fuel management system for a biomass furnace
CN113218233A (zh) * 2021-04-06 2021-08-06 关学忠 一种加热炉火管清垢防垢方法及防垢装置

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DE69943109D1 (de) 2011-02-17
EP1112460A1 (de) 2001-07-04
US6959654B2 (en) 2005-11-01
WO2000011402A1 (en) 2000-03-02
EP1112460B1 (de) 2011-01-05
EP1112460A4 (de) 2004-12-15
ATE494512T1 (de) 2011-01-15
US20020174811A1 (en) 2002-11-28
US20030089288A1 (en) 2003-05-15
US6532879B2 (en) 2003-03-18

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