Three-stage energy-integrated product gas generation system

Patent metadata

Field	Value
Publication number	US-2019016961-A1
Application number	US-201816135069-A
Country	US
Kind code	A1
Filing date	Sep 19, 2018
Priority date	Mar 25, 2016
Publication date	Jan 17, 2019
Grant date	—

Abstract

A multi-stage product gas generation system converts a carbonaceous material, such as municipal solid waste, into a product gas which may subsequently be converted into a liquid fuel or other material. One or more reactors containing bed material may be used to conduct reactions to effect the conversions. Unreacted inert feedstock contaminants present in the carbonaceous material may be separated from bed material using a portion of the product gas. A heat transfer medium collecting heat from a reaction in one stage may be applied as a reactant input in another, earlier stage.

First claim

What is claimed is:

1 . A three-stage energy-integrated product gas generation system ( 1001 ) configured to produce a product gas from a carbonaceous material ( 102 ), the system comprising:
(a) a first reactor ( 100 ) having a first interior ( 101 ) and comprising:
a first reactor carbonaceous material input ( 104 ) to the first interior ( 101 );
a first reactor reactant input ( 108 ) to the first interior ( 101 ), and
a first reactor product gas output ( 124 );
(b) a second reactor ( 200 ) having a second interior ( 201 ) and comprising:
a second reactor char input ( 204 ) to the second interior ( 201 ), in fluid communication with the first reactor product gas output ( 124 );
a second reactor oxygen-containing gas input ( 220 ) to the second interior ( 201 );
a second reactor product gas output ( 224 ); and
a second reactor heat exchanger (HX-B) in thermal contact with the second interior ( 201 ), the second reactor heat exchanger comprising a second reactor heat transfer medium inlet ( 212 ) and a second reactor heat transfer medium outlet ( 216 ), the second reactor heat transfer medium outlet ( 216 ) being in fluid communication with the first reactor reactant input ( 108 ); and
(c) a third reactor ( 300 ) having a third interior ( 301 ) and comprising:
one or more product gas inputs ( 303 , 304 , 305 ) to the third interior ( 301 ), in fluid communication with the first and second product gas outputs ( 124 , 224 );
a third reactor oxygen-containing gas input ( 320 ) to the third interior ( 301 );
a third reactor product gas output ( 336 ); and
a third reactor heat exchanger (HX-C) in thermal contact with the third interior ( 301 ), the third reactor heat exchanger comprising a third reactor heat transfer medium inlet ( 312 ) and a third reactor heat transfer medium outlet ( 316 ), the third heat transfer medium outlet ( 316 ) being in fluid communication with the second reactor heat transfer medium inlet ( 212 );
wherein:
the third reactor heat exchanger (HX-C) is configured to receive a heat transfer medium ( 310 ) at a third reactor inlet temperature (TO) via the third reactor heat transfer medium inlet ( 312 ); and
a first portion of the heat transfer medium ( 310 ) passes through the third reactor heat exchanger (HX-C) and then the second reactor heat exchanger (HX-B) before being introduced, into the first interior ( 101 ) via the first reactor reactant input ( 108 ), as a reactant ( 100 ) at a first reactor reactant temperature (TR 1 ), the first reactor reactant temperature (TR 1 ) being higher than the third reactor inlet temperature (T 0 ).

2 . The three-stage product gas generation system ( 1001 ) according to claim 1 , further comprising:
a second reactor reactant input ( 208 ) to the second interior ( 201 ); wherein: the second reactor reactant input ( 208 ) is in fluid communication with the second reactor heat transfer medium outlet ( 216 ) and is configured to introduce at least a portion ( 206 A) of said heat transfer medium ( 310 ) into the second interior ( 201 ) as a reactant of the second reactor ( 200 ).

3 . The three-stage energy-integrated product gas generation system ( 1001 ) according to claim 1 , further comprising:
a first reactor oxygen-containing gas input ( 120 , 120 A, 120 B, 120 C) to the first interior ( 101 ) and configured to receive a first reactor oxygen-containing gas ( 118 ).

4 . The three-stage energy-integrated product gas generation system ( 1001 ) according to claim 1 , further comprising a first solids separation device ( 150 ) having:
a first separation input ( 152 ) in fluid communication with the first reactor product gas output ( 124 ); a first separation char output ( 154 ) in fluid communication with the second reactor char input ( 204 ); and, a first separation gas output ( 156 ).

5 . The three-stage energy-integrated product gas generation system ( 1001 ) according to claim 4 , further comprising a second solids separation device ( 250 ) having:
a second separation input ( 252 ) in fluid communication with the second reactor product gas output ( 224 ); a second separation solids output ( 254 ) in fluid communication with a solids transfer conduit ( 234 ); and, a second separation gas output ( 256 ).

6 . The three-stage energy-integrated product gas generation system ( 1001 ) according to claim 5 , further comprising:
a combined reactor product gas conduit ( 230 ) in fluid communication with both the first separation gas output ( 156 ) and the second separation gas output ( 256 ) and configured to combine product gas created by both the first reactor ( 100 ) and the second reactor ( 200 ).

7 . The three-stage energy-integrated product gas generation system ( 1001 ) according to claim 1 , wherein the first interior comprises:
a first reactor dense bed zone (AZ-A); a first reactor feed zone (AZ-B) located above the first reactor dense bed zone; and, a first reactor splash zone (AZ-C) located above the first reactor feed zone.

8 . The three-stage energy-integrated product gas generation system ( 1001 ) according to claim 7 , further comprising:
a first reactor dense bed zone reactant input ( 108 A) configured to receive a first reactor dense bed zone reactant ( 106 A) into the first reactor dense bed zone (AZ-A); a first reactor feed zone reactant input ( 108 B) configured to receive a first reactor feed zone reactant ( 106 B) into the first reactor feed zone (AZ-B); and a first reactor splash zone reactant input ( 108 C) configured to receive a first reactor splash zone reactant ( 106 C) into the first reactor splash zone (AZ-C).

9 . The three-stage energy-integrated product gas generation system ( 1001 ) according to claim 8 , further comprising:
at least three first reactor feed zone reactant inputs; and, at least three first reactor splash zone reactant inputs.

10 . The three-stage energy-integrated product gas generation system ( 1001 ) according to claim 7 , further comprising:
a first reactor dense bed zone oxygen-containing gas input ( 120 A) configured to receive a first reactor oxygen-containing gas ( 118 A) into the first reactor dense bed zone (AZ-A); a first reactor feed zone oxygen-containing gas input ( 120 B) configured to receive a first reactor feed zone oxygen-containing gas ( 118 B) into the first reactor feed zone (AZ-B); and a first reactor splash zone oxygen-containing gas input ( 120 C) configured to receive a first reactor splash zone oxygen-containing gas ( 118 C) into the first reactor splash zone (AZ-C).

11 . The three-stage energy-integrated product gas generation system ( 1001 ) according to claim 10 , comprising:
at least three first reactor feed zone oxygen-containing gas inputs; and, at least three first reactor splash zone oxygen-containing gas inputs.

12 . The three-stage energy-integrated product gas generation system ( 1001 ) according to claim 1 , wherein the second interior comprises:
a second reactor dense bed zone (BZ-A); a second reactor feed zone (BZ-B) located above the second reactor dense bed zone; and, a second reactor splash zone (BZ-C) located above the second reactor feed zone.

13 . The three-stage energy-integrated product gas generation system ( 1001 ) according to claim 12 , further comprising:
a second reactor dense bed zone reactant input ( 208 A) configured to receive a second reactor dense bed zone reactant ( 206 A) into the second reactor dense-bed zone (BZ-A); a second reactor feed zone reactant input ( 208 B) configured to receive a second reactor feed zone reactant ( 206 B) into the second reactor feed zone (BZ-B); and, a second reactor

Assignees

• Thermochem Recovery Int Inc

Inventors

• Chandran Ravi
• Burciaga Daniel A
• Leo Daniel Michael
• Freitas Shawn Robert
• Newport Dave G
• Miller Justin Kevin
• Harrington Kaitlin Emily
• Attwood Brian Christopher

Classifications

• C10J2300/1253

  by injecting hot gas · CPC title

• C10J2300/094

  Char · CPC title

• C10J3/721

  Multistage gasification, e.g. plural parallel or serial gasification stages · CPC title

• C10B53/07 Primary

  {of solid raw materials consisting} of synthetic polymeric materials, e.g. tyres (recovery or working-up of waste materials of organic macromolecular compounds or compositions based thereon by dry-heat treatment for obtaining partially depolymerised materials C08J11/10; production of liquid hydrocarbon mixtures from rubber or rubber waste C10G1/10) · CPC title

• C10J2300/1223

  by burners · CPC title