US20070289507A1

US20070289507A1 - System, method and apparatus for pyrolizing waste material

Info

Publication number: US20070289507A1
Application number: US11/808,790
Authority: US
Inventors: William Parrott; Elzie Schoepf; Jeff Reinders
Original assignee: Alternative Power Solutions Inc
Current assignee: Alternative Power Solutions Inc
Priority date: 2006-06-16
Filing date: 2007-06-13
Publication date: 2007-12-20
Also published as: WO2008005171A3; WO2008005171A2

Abstract

A system, method and apparatus for pyrolyzing are disclosed. The system, method and apparatus can include a plurality of chambers which may be loaded with material to be pyrolyzed. The material may then be pyrolyzed to produce a gaseous fuel and any remaining material in any of the plurality of chambers may be removed. The gaseous fuel may be sent to an afterburner where other elements may be added to generate heated gas having a predetermined temperature. The heated gas may be used in any of a variety of devices, such as a heat exchanger or a dryer, and may be used for any of a variety of reasons, such as the generation of heat.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This invention claims priority to U.S. Provisional Patent Application No. 60/814,673, entitled EQUIPMENT, SYSTEM & METHOD OF PYROLIZING WASTE MATERIAL, and filed Jun. 16, 2006, the entire contents of which are hereby incorporated by reference.

FIELD OF THE INVENTION

This invention relates generally to the field of gas pyrolysis and, in particular, to the field of gas pyrolysis that results in a usable end product.

BACKGROUND

Pyrolysis is a thermal distillation or decomposition process that generally involves the conversion of waste material into carbon black residue through a chemical change by the action of heat on the waste material. The chemical change is often brought about in waste materials containing volatile and nonvolatile higher molecular weight materials that break down into lower molecular weight, volatile, combustible materials upon heating. The process is often used to reduce the physical amount of mass of solid waste material that needs to be housed or disposed of, for example, in a landfill. This process is becoming more common as the amount of space for landfills decreases and as the general public gains more awareness about their surroundings and frequently object to the presence of a landfill close to any residential or metropolitan area for fear of contamination. Other uses of pyrolysis include cleaning oil-contaminated soil, drying wet organic materials, such as animal manure or sewage plant sludge, and generally serving as a heat source for processes that make use of hot gases as an energy source.
Current methods of pyrolysis are used on solid waste materials such as tires. Current pyrolysis methods used for such materials encounter a variety of problems, however. Some methods do not efficiently pyrolize the desired materials while others generate unacceptable amounts of residue or residue that is otherwise undesirable. The efficiency of current pyrolysis machines and techniques is also poor as it takes a significant amount of time to load, pyrolize and unload a pyrolysis machine or device. Additional manpower must also be associated with these tasks in order to attempt to retain some efficiency in the process.
Still other pyrolysis machines and methods achieve poor results due to non-uniform heating and pyrolizing of waste material. Efficiency may be lost and the desired results may not be obtained when portions of waste material are, for example, improperly heated or combusted when other portions of waste material are properly heated and combusted.
Other pyrolysis machines and methods have a variety of other drawbacks, including poor sealing, poor volume capability, and inefficient use of byproducts.

SUMMARY

An exemplary embodiment of this invention relates to a system for combusting materials. The system may include a plurality of housings having a plurality of zones and accepting a material as fuel and converting the material into a gaseous fuel. The system may also have an afterburner that may accept the gaseous fuel from the plurality of housings and air and may convert the gaseous fuel and air into heat.
Another exemplary embodiment of the invention may include a method of generating heat energy. The method of generating heat energy can include the loading of pyrolysis chamber with a solid material as well as the converting of the solid material into a gaseous fuel through pyrolysis. The method may go on to move the gaseous fuel to an afterburner and may further combine the gaseous fuel with air in the afterburner. Also, the method can include a step of combusting the combined gaseous fuel and air in the afterburner to generate heat. Further, in some exemplary embodiments, the heat generated in the afterburner may be used an energy source.
In yet another exemplary embodiment, a system for producing energy may be described. The system can include means for pyrolizing waste material, means for loading waste material and means for unloading non-pyrolized material. The system may also have means for extracting a gaseous fuel from the means for pyrolizing waste material. Also, the system can incorporate means for moving the gaseous fuel to a means for producing heat energy.

BRIEF DESCRIPTION OF THE DRAWINGS

Advantages of embodiments of the present invention will be apparent from the following detailed description of the exemplary embodiments thereof, which description should be considered in conjunction with the accompanying drawings in which:

FIG. 1 is an exemplary diagram showing a flow of pyrolized materials.

FIG. 2 is an exemplary diagram of a pyrolization system.

FIG. 3 is an exemplary diagram of a pyrolysis chamber.

FIG. 4 is an exemplary external view of a pyrolysis chamber.

FIG. 5 is an exemplary rotated, external view of a pyrolysis chamber.

FIG. 6 is an exemplary view of a conduit that may be used mixing a gaseous fuel and air.

FIG. 7 is another exemplary view of a conduit that may be used for mixing a gaseous fuel and air.

FIG. 8 is an exemplary diagram of an afterburner.

FIG. 9 is an exemplary diagram of another pyrolization system.

DETAILED DESCRIPTION

Aspects of the invention are disclosed in the following description and related drawings directed to specific embodiments of the invention. Alternate embodiments may be devised without departing from the spirit or the scope of the invention. Additionally, well-known elements of exemplary embodiments of the invention will not be described in detail or will be omitted so as not to obscure the relevant details of the invention. Further, to facilitate an understanding of the description discussion of several terms used herein follows.
The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments. Likewise, the terms “embodiments,” “embodiments of the invention,” “exemplary embodiments” and similar terms do not require that all embodiments of the invention include the discussed feature, advantage or mode of operation.
Generally referring to FIGS. 1-9, a system, method and apparatus for pyrolysis are shown. The system, method and apparatus may include any number of components and may be able to produce a gaseous fuel.
In a first exemplary embodiment, as shown in FIG. 1, a system, method and apparatus for pyrolysis are shown. Apparatus 100 may be used as a stand-alone unit that may produce a gaseous fuel. The gaseous fuel may be used for any of a variety of purposes, for example the production of steam or the production of heat. The apparatus 100 may have any number of pyrolysis chambers, for example chambers 102, 104 and 106. Pyrolysis chambers 102, 104 and 106 may be substantially similar and may include similar outputs within apparatus 100. It should also be noted that any number of pyrolysis chambers or housings may be used with apparatus 100. For example, some exemplary embodiments may utilize one pyrolysis chamber, while other exemplary embodiments may use two, three, four, or more pyrolysis chambers, as desired to achieve any amount of desired pyrolysis. Each of pyrolysis chambers 102, 104 and 106 may be used to produce a gaseous fuel. The gaseous fuel that may be produced by the pyrolysis chambers may be fed to other components of apparatus 100. For example, in one embodiment, the gaseous fuel produced in pyrolysis chambers 102, 104 and 106 may be fed downstream to afterburner 138. Afterburner 138 may ignite the gas using an outside fuel source and pilot light 139, which may then allow afterburner 138 to generate heat which may be sent to heat exchanger 140. Heat exchanger 140 may use the heat generated by after burner 138 to produce an output, such as steam 142.
As further shown in exemplary FIGS. 2-5, pyrolysis chambers 102, 104 and 106 may have doors or openings located at top portions of the respective chambers. For example, pyrolysis chambers 102 and 106 are shown with doors 103 and 107, respectively, in an “open” position while pyrolysis chamber 104 is shown with door 105 in a “closed” position. However, any or all of pyrolysis chambers 102, 104 and 106 may have doors 103, 105 and 107, respectively, in an open position simultaneously or in a closed position simultaneously. In the exemplary embodiments shown in FIGS. 1 and 2, pyrolysis chamber 102 may have door 103 in an open position so as to facilitate the loading of any material into pyrolysis chamber 102. Also, pyrolysis chamber 106 may have door 107 in an open position so as to allow for the removal of any waste material from pyrolysis chamber 106. Further, pyrolysis chamber 104 may have door 105 in a closed position so as to allow for the pyrolysis of any material disposed in pyrolysis chamber 104.
The material disposed in any pyrolysis chamber may be any type of material that is desired to be pyrolized, for example any type waste material. In some exemplary embodiments, the waste material can include any type of trash or garbage, petroleum and petroleum-related materials, such as plastics, manure, or combinations of materials, such as tires that utilized steel belts. In further exemplary embodiments, any grouping of material found at a landfill may be used in this method, system and apparatus. At any time when a pyrolysis chamber, such as any of pyrolysis chambers 102, 104 or 106, is not being used to pyrolize, its door may be opened and waste material may be deposited into a pyrolysis chamber. The waste material may then be pyrolized and converted into energy.
In a further exemplary embodiment, one pyrolysis chamber may be loaded with waste material while another pyrolysis chamber is pyrolizing material and yet another chamber is being unloaded. For example, as shown in FIG. 2, waste material may be loaded into pyrolysis chamber 102. Simultaneously, waste material may be pyrolized in pyrolysis chamber 104. Further, at the same time, any remnants of pyrolized material may be removed from pyrolysis chamber 106. The remnants of pyrolized material, for example the material being unloaded from chamber 106, may include incombustibles and residue carbon black, as non-limiting examples. This material may be cooled, removed from the chamber and then reloaded into a pyrolysis chamber with other waste material that may be subsequently pyrolized.
Additionally, as shown in exemplary FIGS. 2-3, any of a plurality of a pyrolysis chambers, such as chambers 102, 104 and 106, may be substantially similar and any description of various aspects of any pyrolysis chamber may be applied or attributed to any of the other chambers. In one exemplary embodiment, pyrolysis chamber 102 may be packed or filled with any amount of waste material. A combustible fuel may then be introduced into chamber 102. The combustible fuel may be any fuel, for example propane, and may be pressurized before being introduced into chamber 102. In some exemplary embodiments, the fuel, such as propane, may be stored in a container, such as tank 202. Tank 202 may be coupled with interior 204 of chamber 102 in such a manner as to provide a supply of the fuel housed in tank 202 to interior 204. For example, tank 202 may be connected to fuel supply line 206 through nozzle 208. Supply line 206 may further connect to nozzle 210, through which the combustible fuel may exit into interior 204 of chamber 102. Nozzles 208 and 210 may be any type of nozzles known to one having ordinary skill in the art and may be automatically or manually controlled. For example, in some embodiments, nozzles 208 and 210, as well as any other nozzles or valves described herein, may open or close in response to one or more conditions that may be present in apparatus 100. Additionally, in further exemplary embodiments, an ignition device mounted in interior 204 of chamber 102 may be used to ignite the combustible fuel. The ignition device may be any type of ignition device known to one having ordinary skill in the art, for example an electronic ignition mechanism. After the ignition device ignites the combustible fuel, the material inside chamber 102 may be ignited and the combustion process may begin. Combustible fuel may be continuously fed into chamber 102 until a desired rate of combustion or amount of combustion is achieved. This may be any amount of time as needed to produce the desired combustion, for example ten minutes.
The combustion in chamber 102, or any other chamber, may be controlled to provide sufficient heat for the production of a gaseous fuel from the combusted materials through pyrolysis. In one exemplary embodiment, a limited amount of heat may be employed to produce the gaseous fuel. Here, the heat in chamber 102 may be regulated, for example, through the metering of air that may be fed into chamber 102. Likewise, heat regulation may be achieved by any method known to one having ordinary skill in the art. Thus, the temperature in chamber 102 may be kept in a desired range. The desired range in some exemplary embodiments may be between about 125 and about 850 degrees Fahrenheit. In some further exemplary embodiments, a temperature of about 350 degrees Fahrenheit may be used.
The metering or regulating of air in chamber 102 may be accomplished in any of a variety of ways. For example, air may be introduced at different locations with heating zones 108, 110, 112, 114 and 116 in a controlled manner. As shown in FIG. 2, air may be introduced to the heating zones through the use of fan 143 and valves 117. Similarly, heating zones 118-126 in chamber 104 may be cooled by valves 127, which may be fed air by fan 145 and heating zones 128-136 may be cooled by valves 137, which may be fed air by fan 147. The introduction of air may further be used to make the temperature in any heating zones, such as zones 108-116, uniform. For example, if a portion of the waste material is burning at a higher temperature in one zone, e.g. zone 110, more air may be introduced in the other zones so as to increase the combustibility and increase the temperature. Similarly, less air may be provided to an area having a high temperature so that the temperature of that area may be lowered. The regulation of the airflow may be performed in any of a variety of manners, for example using a plurality of automatically activated air supplies connected to a plurality of temperature sensors and coupled to processor or controller.
In a further exemplary embodiment, fan 143 may be used to supply air to the various zones of chamber 102. Fan 143 may be coupled with an external duct, for example, external duct 213 outside of chamber 102. Fan 143 may blow the air though external duct 213, for example at a pressure that may be slightly above ambient pressure. The air may be directed through duct 213 to a variety of plenum sections, for example plenum sections 212, 216, 218, 220 and 220, which may correspond to zones 108, 110, 112, 114, and 116, respectively. Each of plenum sections 214-222 may be in fluid communication with the atmosphere using the control of a plurality of intermittently operated valves, for example valves 222, 224, 226, 228 and 230, respectively. Valves 222-230 may further be located at different locations of duct 213. Thus, in one exemplary embodiment, fan 143 may produce airflow through duct 213. The airflow may then pass through valve 222, if valve 222 is opened, into plenum 212. Air may then be introduced into zone 108 of chamber 102 from plenum 212. In some exemplary embodiments, valves may be located at any portion of plenum 212, for example at opposite ends, through which air may enter zone 108. Similarly, air may be introduced to zones 110, 112, 114 and 116 using corresponding airflow paths leading into the respective chambers.
As described previously, the temperature within each of zones 108-116 may be continuously monitored through any of a variety of temperature sensors, for example by thermal couples 232, 234, 236, 238 and 240, respectively. Corresponding thermal couples may be located in chambers 104 and 106. Additionally, thermal couples may be located anywhere within zones 108-116, for example on a floor, ceiling or wall of an individual zone. More than one thermal couple may also be used in a zone, if desired. Further, thermal couples 232-240 may be operably coupled with valves 222-230, respectively. Valves 222-230 may be used to regulate airflow into corresponding zones 108-116 in response to the readings made by thermal couples 232-240, respectively. The temperature in each zone may therefore be maintained within a desired pyrolysis temperature range of the waste material undergoing combustion. Airflow may be directed into any zones 108-116, or any combination thereof, via any desired number of inlets, such as those described with respect to FIGS. 4-5 below. The inlets may be disposed in any location in zones 108-116, for example located on side portions of the zones, and may be able to provide airflow in any direction, for example towards a lower section of the zones.
In a further exemplary embodiment, a pyrolysis temperature range may be maintained with chamber 102 and any of zones 108-116 by varying, reducing or discontinuing the flow of air into individual zones. Additionally, as the introduction of air may help the production of a gaseous fuel in chamber 102 some zones may receive a certain amount of airflow while others receive an increased, decreased or eliminated amount of airflow.
In a further exemplary embodiment, through the pyrolysis, most of the carbon-containing substances found in the waste material may be converted into a gaseous fuel. The gaseous fuel may flow from chamber 102 through outlet 144. Outlet 144 may be located on the periphery of chamber 102. Similarly, chambers 104 and 106 may each have a similar outlet, such as outlets 146 and 148, respectively. Outlets 144, 146 and 148 may each have filters disposed therein. The filters in outlets 144, 146 and 148 may act to prevent any particulates, debris, residue or any other solid matter in any gaseous fuel that exits chambers 102, 104 or 106, respectively, from migrating to the afterburner 138. The filters used in outlets 144, 146 and 148, as well as filters that may be positioned or disposed in any other location on device 100, may be any type of filter known to one having ordinary skill in the art. Additionally, any particulates, for example carbon black, may be captured and supplied for any of a variety of uses.
Following the pyrolysis of waste material and the outputting of any gaseous fuel, metals or other incombustible materials may remain in chamber 102, along with carbon black residue. As described previously, any materials remaining in chamber 102 may be removed in order to be pyrolized again or otherwise disposed of.
In yet another exemplary embodiment, subsequent to converting the waste material into a gaseous fuel, chamber 102 may be cooled to a substantially ambient temperature. Any remaining material may be removed from chamber 102 after it is cooled. In one exemplary embodiment, water may be sprayed into chamber 102, including any of zones 108-116, to further cool any remaining materials and to reduce the amount of carbon black residue that may blow around as any larger, solid materials are being removed from chamber 102. For example, tubing 236 may be coupled to water reservoir 238. Tubing 236 may extend to various portions of zones 108-116. Additionally, a plurality of nozzles 242 may be connected to tubing 236 and may allow for the spraying or disbursement of water into the various zones. Thus, if it may be desired to spray water into zones 108-116, valve 240, which may couple tubing 236 with water reservoir 238, may be opened and water may be distributed to various nozzles 242 and sprayed on any remaining residue in chamber 102. Because the residue remaining in chamber 242 may still be hot, steam may be generated within chamber 102. Therefore, in order to let any steam escape, a cover over vent 234 may be opened, and steam may escape from chamber 102 through these holes. Vent 234 may be any type of vent, for example a screen, a plurality of holes, an opening or any other type of vent known to one having ordinary skill in the art. Also, as described below with respect to FIG. 5, vent 234 may be associated with a door that may be used to close and seal vent 234. Further, in this embodiment, any remaining metals may be separated, either manually or automatically, from any remaining carbon black residue. For example, in one embodiment, a magnet may be used to separate and remove any iron-based metals from the remaining incombustible materials.
In another exemplary embodiment, as shown in FIG. 4, chamber 102, as well as any other chambers, may be constructed and formed in any of a variety of manners. For example, chamber 102 may have a box-like configuration. Chamber 102 may further include doorway 103, as described previously. Doorway 103 may provide access to any remaining materials following the cooling of chamber 102 after the gaseous fuel is produced. Doorway 103 may include doors 402 and 404, which may be formed in any manner known to one having ordinary skill in the art, for example with hinges 406 that couple with sidewalls of chamber 102, which may allow the two doors 404 and 406 to be opened outward. Additionally, when doors 404 and 406 are closed, a seal may be made so that the gaseous fuel produced within chamber 102 may not escape through any coupling of a door or doors to any other portion of chamber 102.
In a further exemplary embodiment, portions of chamber 102 may be formed using steel plates that are welded together to form chamber 102. Additionally, an interior portion of chamber 102 may have an interior surface lined with a refractory substance that may provide insulation. The refractory or insulating material, which may be any refractory or insulating material known to one having ordinary skill in the art, such as concrete, may be cast so as to line any amount of the interior of chamber 102. Also, as described previously, an ignition device may be located on any portion of the interior of chamber 102, for example a rear wall opposite door 103. Also, chamber 102 may have any dimensions, depending on the desired amount of waste material to pyrolize or the amount of gaseous fuel to be produced. In one exemplary embodiment, chamber 102 may have a height of about seven feet to about twelve feet, a width of about six feet to about sixteen feet and a length of about ten feet to about twenty four feet.
FIG. 5 provides an exemplary top-down view of a pyrolysis chamber. In this exemplary view, doors 402 and 404 may be closed, and may therefore be flush with the exterior of chamber 102. Also, outlet 144 may be shown at a bottom portion of chamber 102 in this exemplary embodiment. Further, vent 234 may be positioned on a top portion of chamber 102, and may include vent cover 502. When closed, vent cover 502 may seal vent 234, which can prevent the release of any gases or material inside chamber 102 to an outside environment. However, if vent cover 502 is opened, vent 234 may be open and therefore contents of chamber 102, for example steam that results from the liquid cooling of any remaining waste material following pyrolysis, may flow through vent 234 as exhaust gas. Also, as may be seen in this exemplary view, duct segments 408 and 410, described in more detail below, may be seen as routed along a perimeter portion of chamber 102.
Chamber 102 may be connected to any of a variety of external ducts which may be used for any of a variety of reasons. Some of these ducts may be connected to outside fans that may provide air to apparatus 100 at a pressure slightly above ambient. This air may be used to regulate the temperature in any or all of zones 108-116. For example, duct 407 may include duct segment 408 and duct segment 410. Duct segment 408 and duct segment 410 may be substantially U-shaped and may connect to other ducts mounted on chamber 102. Further, as shown in exemplary FIGS. 4 and 5, duct 407, including duct segments 408 and 410, may be connected to duct members 504 and 506 so as to substantially surround chamber 102. These external ducts may be coupled to plenum sections 212, 214, 216, 218 and 220 and may be used to provide air to zones 108, 110, 112, 114 and 116. Additionally, any number of ducts may be disposed on an interior portion of chamber 102 and may allow for the collection of the gaseous fuel produced by the pyrolysis and may later connect to outlet 144. Additionally, any number of apertures may be located in any of a variety of locations, for example a ceiling portion, of each of zones 108-116 so as to allow any desired gases to escape chamber 102 and flow out of apparatus 100.
In a further exemplary embodiment shown in FIG. 3, the interior of chamber 102 may be substantially open. For example, although there may be any number of zones, such as zones 108-116, there may be no internal barriers between any of the zones and the zones may extend from a floor portion to a ceiling portion of chamber 102. The zones may be oriented and sized in any manner. In one exemplary embodiment, zone 108 may be positioned proximate door 103 and may account for about twenty percent of the volume of the interior of chamber 102. Zones 112 and 114 may be proximate outlet 144 and may each account for about twenty percent of the volume of the interior of chamber 102. Zones 110 and 116 may be located substantially between zone 108 and zones 112 and 114. Zones 110 and 116 each may also account for about twenty percent of the interior volume of chamber 102. Additionally, vent 234 may be located in a position that occupies portions of zones 110-116. Vent 234 may, in some exemplary embodiments, include a vent cover, such as vent cover 502 described above, that may prevent any gases from escaping chamber 102. Additionally, chamber 102 may be filled to any volume prior to the start of the pyrolysis process and, in some exemplary embodiments, may have about eighty to ninety percent of its volume filled with any type of desired waste material.
As discussed previously, and as further shown in exemplary FIGS. 6-8, after the gaseous fuel is produced in any of chambers 102, 104 or 106, the gaseous fuel may be sent to afterburner 138. The gaseous fuel may be sent down any conduits, for example coaxial conduits 150 and 152. Coaxial conduits 150 and 152 may also carry fresh air or any other gas in a mixture with the gaseous fuel. Coaxial conduit 150 may also be coupled with an outlet of fan 154, which may be used to propel the gaseous fuel towards the afterburner 138. Additionally, coaxial conduit 152 may be coupled to coaxial conduit 150 and may receive the gaseous fuel from coaxial conduit 150. Additionally, coaxial conduit may be coupled to fan 156, which may further propel the gaseous fuel towards afterburner 138 and may also provide a mixture of fresh air with the gaseous fuel.
In a further exemplary embodiment, coaxial conduit 150 may have a larger diameter than coaxial conduit 152, which may allow for the presence of open space around the periphery of coaxial conduit 152. In this embodiment, coaxial conduit 152 may provide a sealed path through which fresh air generated by fan 156 may enter afterburner 138 as coaxial conduit may run through an interior portion of coaxial conduit 150. Similarly, coaxial conduit 150 may provide gaseous fuel directly to afterburner 138 through the space around the periphery of coaxial conduit 152. Thus any desired mixture of gaseous fuel and air may be provided at afterburner 138.
In yet a further exemplary embodiment shown in FIG. 8, afterburner 138 may have pilot light 802 that is fed a combustible fuel from an external fuel supply through conduit 804. When lit, pilot light 802 may be used to ignite any mixture of gaseous fuel and air that may be delivered to afterburner 138. The pilot light 802 may be extinguished or otherwise turned off after the mix of gaseous fuel and air is combusted or converted into hot gas. For example, in some embodiments, afterburner 138 may produce a hot gas have a temperature of about 1500 degrees Fahrenheit to about 2800 degrees Fahrenheit.
In another exemplary embodiment, device 100 may produce steam. As described above, afterburner 138 may burn a combination of gaseous fuel and air. The burning of the gaseous fuel and air may produce heat for heat exchanger 140. For example, after the gaseous fuel is substantially completely combusted in afterburner 138, the heat produced thereby may be used to boil water in heat exchanger 140 to generate steam. Heat exchanger 140 may also include a low water cut-off valve 158 which may be actuated to stop operation of heat exchanger 140 if a water level in heat exchanger 140 gets too low.
In a further exemplary embodiment, gaseous fuel from a pyrolysis chamber, for example chamber 102, 104, or 106, may be fed to afterburner 138 through coaxial conduit 150 using fan 154, which may be a variable speed induction fan. The gaseous fuel may be mixed with fresh air that may be fed to afterburner 138 through coaxial conduit 152 by fan 156, which may be a variable speed fresh air fan. Fan 154 may be coupled with line 160, which may feed gaseous fuel into fan 154. Fan 154 may run continuously or non-continuously, and may run at any speed. In one exemplary embodiment, fan 154 may run continuously but its speed may be varied for any of a variety of factors. Some of these factors can include the increase or decrease of steam pressure in heat exchanger 140, as determined by pressure sensor and controller 162. Pressure sensor and controller may continuously monitor the steam pressure in heat exchanger 140 and may relay a signal to fan 154 to vary its speed depending on the pressure in heat exchanger 140. Pressure sensor and controller 162, as well as any other sensor, may be any type of sensor known to one having ordinary skill in the art.
Referring back to FIG. 2, common line 160 may be fed gaseous fuel from any of output lines 164, 166 or 168, which may be coupled to the outputs of chambers 102, 104 and 106, respectively. Output lines 164, 166 and 168 may also be coupled to valves or dampers 165, 167 and 169, respectively. Valves 165, 167 and 169 may be electronically operated and may control the flow of any gaseous fuel from any of the chambers to line 160. Additionally, one or more valves, such as valves 170 and 172, may be located on line 160. In one exemplary embodiment, valve 170 may be located on line 160 between chamber 102 and chamber 104 and valve 172 may be located on line 160 between chamber 104 and chamber 106. Valves 170 and 172 may also be electronically operated and may control the flow of any gaseous fuel along line 160.
Further downstream in device 100, valve 176 may be disposed on line 174 between afterburner 138 and heat exchanger 140. Valve 176 may be used to regulate the flow of hot gas from afterburner 138 to heat exchanger 140. During operation, valve 176 may typically be in the open position. However, if desired, valve 176 may be closed, which may prevent the flow of hot gas from afterburner 138 to heat exchanger 140. If valve 176 is closed, hot gas may optionally, in some exemplary embodiments, be routed through bypass piping (not shown). However, when valve 176 is open, valve 180 may typically be closed, thus allowing hot gas to enter heat exchanger 140.
In another exemplary embodiment, device 100 may be able to respond to a demand for heat from heat exchanger 140. The response to a request for additional heat may be to draw gaseous fuel as needed from one or more of pyrolysis chambers 102, 104 and 106. For example, if it is desired that heat exchanger 140 provide steam at one hundred pounds per square inch (PSI), an increase in steam consumption may be reflected by a corresponding decrease in steam pressure. Pressure sensor and controller 162 may signal a fan 156, and fan 156 may provide additional air to afterburner 138. The change in the amount of air being directed to afterburner 138 may raise the temperature of the hot gas exiting afterburner 138. Consequently, the steam pressure in heat exchanger 140 may be increased. Likewise, if the demand for steam pressure lessens, fan 156 may decrease the amount of air it is sending to afterburner 138, which may lower the temperature of the hot gas and ultimately may lower the steam pressure in heat exchanger 140.
Similarly, in a further exemplary embodiment, if more air is directed from fan 156 to afterburner 138, more gaseous fuel may be drawn from chambers 102, 104 and 106 to afterburner 138. In this embodiment, temperature controller 182 may monitor the temperature of the hot gas exiting afterburner 138. Temperature controller 182, in response to the temperature of the hot gas, may regulate the flow of the hot gas into afterburner 138 of both fresh air directed from fan 156 and gaseous fuel from pyrolysis chambers 102, 104 and 106. Temperature controller 182 may be able to signal both fan 154 and fan 156, which may have their speeds varied to control the amount of gaseous fuel and air entering afterburner 138, respectively.
In yet another exemplary embodiment shown in FIG. 2, pressure regulator 184 may monitor the pressure of the hot gas exiting afterburner 138. In some embodiments, the pressure of the hot gas may be high enough to overcome any backpressure from heat exchanger 140. Pressure regulator 184 may be operatively coupled to fan 186, which may be an induction fan, in heat exchanger 140, and may be able to vary the speed of fan 186. Fan 186 may be activated by pressure regulator 184 at any time, for example when the pressure of the hot gas is too low to overcome the backpressure in heat exchanger 140. In such a situation, fan 186 may be activated or have its speed increased by pressure regulator 184 to act as an induction device to draw the hot gas into the heat exchanger 140. Additionally, in some exemplary embodiments, temperature controller 182 may have a setting whereby if the temperature of the hot gas from afterburner 140 exceeds a predetermined temperature, device 100 may be shut down or the hot gas may be recycled within device 100. This temperature may be about 2800 degrees Fahrenheit.
Again referring to FIG. 2, in yet another exemplary embodiment, a series of valves may be used to control the flow of gaseous fuel from one or more of pyrolysis chambers 102, 104 and 106. For example, when chamber 104 is operating to pyrolize waste material, valve 167 and valve 170 in line 160 may be open. Also, valve 165, valve 169 and valve 172 may be closed. Similarly, when chamber 102 is operating to pyrolize waste material, valve 165 may be open and valve 167, valve 169, valve 170 and valve 172 may be closed. Further, when chamber 106 is operating to pyrolize waste material, valve 169, valve 172 and valve 170 may be open and valve 165 and valve 167 may be closed. In other exemplary embodiments, additional valve that may be associated with bypass lines may be available to route the gaseous fuel to other locations.
Also, each of the valves described herein may operate automatically, for example through the use of sensors or controllers that open and close the valves at appropriate times or otherwise when desired to achieve a desired operation of device 100. Further, the operation of the valves may be used to operate device 100 in an efficient manner, such as actuating the appropriate valves so that chamber 102 may be loaded with waste material to be pyrolized while chamber 104 is pyrolizing waste material and, further, while chamber 106 is being unloaded of any incombustible or non-combusted material.
In another exemplary embodiment, as shown in FIG. 9, device 100 may be used to produce heat 906 for a dryer. In this exemplary embodiment, dryer 902 may be connected to afterburner 138 through line 174 and valve 176. Further, dryer 902 may be any type of dryer known to one having ordinary skill in the art. Device 100 may function similar to that described above in previous embodiments except, in this exemplary embodiment, temperature controller 904 may monitor and sense the temperature in dryer 902 and, based upon the desire to raise or lower the temperature in dryer 902, may activate fan 154. Therefore, if it is desired to increase the temperature of dryer 902 and corresponding output heat 906, temperature controller 904 may send a signal to fan 154 to increase its speed. The increased speed of fan 154 will draw more gaseous fuel to afterburner 138 and cause a corresponding increase in the temperature of dryer 902. Similarly, a signal may be sent to fan 156 so that an increased amount of air may be introduced to afterburner 138, along with an increase in gaseous fuel. Also, if a lower temperature is desired in dryer 902 and corresponding output heat 906, the speed of fan 154 may be decreased, drawing less fuel from a pyrolyzing chamber, and the speed of fan 156 may also be decreased.
In still other exemplary embodiments, heat generated by afterburner 138 may be used as an energy source. Thus, in these exemplary embodiments, any heat generated may be used in any known device, apparatus or method known to one having ordinary skill in the art that may utilize or require heat or may otherwise function with heat or heated gas.
The foregoing description and accompanying drawings illustrate the principles, preferred embodiments and modes of operation of the invention. However, the invention should not be construed as being limited to the particular embodiments discussed above. Additional variations of the embodiments discussed above will be appreciated by those skilled in the art.
Therefore, the above-described embodiments should be regarded as illustrative rather than restrictive. Accordingly, it should be appreciated that variations to those embodiments can be made by those skilled in the art without departing from the scope of the invention as defined by the following claims.

Claims

1. A system for combusting materials, comprising:

a plurality of housings having a plurality of zones and accepting a material as fuel and converting the material into a gaseous fuel; and

an afterburner, the afterburner accepting the gaseous fuel from the first housing, the second housing and the at least third housing and air and converting the gaseous fuel and air into heat.

2. The system of claim 1, wherein the plurality of housings comprises a first housing to convert the material into the gaseous fuel while a second housing is loaded with the material and a third housing has residue remaining from the conversion of the material into the gaseous fuel removed.

3. The system of claim 1, further comprising:

a first fan that provides the air to the afterburner through a conduit.

4. The system of claim 3, wherein the first fan is disposed proximate the afterburner and is automatically controlled to provide varying amounts of air to the afterburner.

5. The system of claim 4, wherein the first fan has its speed decreased when the afterburner is providing heat to the heat exchanger at too high of a temperature and has its speed increased when the afterburner is providing heat to the heat exchanger at too low of a temperature.

6. The system of claim 2, further comprising:

a temperature sensor disposed proximate the afterburner and communicatively coupled with a control unit, the control unit further communicatively coupled with the first fan, and the control unit varying the speed of the first fan based upon temperature readings from the temperature sensor.

7. The system of claim 2, further comprising:

a first pressure sensor disposed proximate the afterburner and communicatively coupled with a control unit, the control unit further communicatively coupled with the first fan, and the control unit varying the speed of the first fan based upon temperature readings from the first pressure sensor.

8. The system of claim 1, wherein the conduit through which air travels from the first fan to the afterburner is disposed inside a second conduit through which the gaseous fuel travels from the first housing, the second housing and the at least third housing to the afterburner.

9. The system of claim 1, further comprising a second fan disposed after a collection area for the gaseous fuel provided by the plurality of housings, the second fan providing varying amounts of gaseous fuel to the afterburner.

10. The system of claim 9, wherein the speed of the second fan is varied to provide varying amounts of gaseous fuel to the afterburner.

11. The system of claim 1, further comprising:

a second pressure sensor communicatively coupled with a control unit;

a third fan disposed proximate the heat exchanger, the control unit varying the speed of the third fan based upon temperature readings from the second pressure sensor.

12. The system of claim 1, further comprising:

a heat exchanger, the heat exchanger receiving heat from the afterburner and heating water to generate steam.

13. A method of generating heat energy, comprising:

loading a pyrolysis chamber with a solid material;

converting the solid material into a gaseous fuel through pyrolysis;

moving the gaseous fuel to an afterburner;

combining the gaseous fuel with air in the afterburner;

combusting the combined gaseous fuel and air in the afterburner to generate heat;

using the heat generated in the afterburner as an energy source.

14. The method of claim 13, further comprising:

moving the gaseous fuel from the pyrolysis chamber to the afterburner using a fan.

15. The method of claim 13, further comprising:

providing air to the afterburner using a fan.

16. The method of claim 13, wherein the pyrolysis occurs at a temperature of about 125 degrees Fahrenheit to about 850 degrees Fahrenheit.

17. The method of claim 13, wherein the afterburner provides heated gas at a temperature between about 1450 Fahrenheit to about 2800 degrees Fahrenheit.

18. The method of claim 13, wherein the afterburner provides heated gas at a temperature of about 1800 degrees Fahrenheit.

19. The method of claim 13, further comprising:

controlling the temperature of the heat generated by the afterburner using a fan.

20. The method of claim 19, further comprising:

varying the speed of the fan to provide more air if the heat generated by the afterburner has too low of a temperature and less air if the heat generated by the afterburner has too high of a temperature.

21. The method of claim 19, further comprising:

detecting a pressure of steam in the heat exchanger; and

regulating the temperature of the heat in the afterburner based upon the pressure of the steam in the heat exchanger.

22. A system for producing energy, comprising:

means for pyrolizing waste material;

means for loading waste material;

means for unloading non-pyrolized material,

means for extracting a gaseous fuel from the means for pyrolizing waste material; and

means for moving the gaseous fuel to a means for producing heat energy.

23. The system of claim 22, wherein waste material is loaded, the waste material is pyrolized and the non-pyrolized material is unloaded simultaneously.