Two-stage energy-integrated product gas generation system and method

• US 10,222,060 B2
• Filed: 08/10/2018
• Issued: 03/05/2019
• Est. Priority Date: 02/16/2016
• Status: Active Grant

• Current Assignee: Thermochem Recovery International, Inc.
• Original Assignee: Thermochem Recovery International, 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
• Primary Examiner(s): Akram, Imran
• Application Number:
  US16/100,258
• Publication Number:
  US 20180347810A1
• Time in Patent Office: 207 Days
• CPC Class Codes: B01J 19/0013 Controlling the temperature of the process
• CPC Class Codes: B01J 19/245 placed in series
• CPC Class Codes: B01J 2208/00132 Tubes
• CPC Class Codes: B01J 2208/00513 using inert heat absorbing solids in the bed
• CPC Class Codes: B01J 2208/0053 Controlling multiple zones along the direction of flow, e.g. pre-heating and after-cooling
• CPC Class Codes: B01J 2219/00076 with heat exchange elements inside the reactor
• CPC Class Codes: B01J 2219/00117 with two or more reactions in heat exchange with each other, such as an endothermic reaction in heat exchange with an exothermic reaction
• CPC Class Codes: B01J 2219/00155 using insulating materials or refractories
• CPC Class Codes: B01J 8/0492 Feeding reactive fluids for solid material, see B01J8/0015
• CPC Class Codes: B01J 8/0496 Heating or cooling the reactor
• CPC Class Codes: B01J 8/1809 Controlling processes
• CPC Class Codes: B01J 8/1818 Feeding of the fluidising gas B01J8/44 takes precedence
• CPC Class Codes: B01J 8/1872 Details of the fluidised bed reactor B01J8/1836 takes precedence
• CPC Class Codes: B01J 8/26 with two or more fluidised beds, e.g. reactor and regeneration installations
• CPC Class Codes: B09B 3/00 Destroying solid waste or transforming solid waste into something useful or harmless
• CPC Class Codes: C01B 3/02 Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen
• CPC Class Codes: C10J 2300/0946 Waste, e.g. MSW, tires, glass, tar sand, peat, paper, lignite, oil shale
• CPC Class Codes: C10J 2300/0969 Carbon dioxide
• CPC Class Codes: C10J 2300/0976 as steam
• CPC Class Codes: C10J 2300/12 Heating the gasifier
• CPC Class Codes: C10J 2300/1215 : using synthesis gas as fuel
• CPC Class Codes: C10J 2300/1253 : by injecting hot gas
• CPC Class Codes: C10J 2300/1659 : to liquid hydrocarbons Fischer-Tropsch process C10G2/00
• CPC Class Codes: C10J 3/482 : Gasifiers with stationary fluidised bed
• CPC Class Codes: C10J 3/721 : Multistage gasification, e.g. plural parallel or serial gasification stages
• CPC Class Codes: C10J 3/723 : Controlling or regulating the gasification process
• CPC Class Codes: C10J 3/84 : with means for removing dust or tar from the gas
• CPC Class Codes: F23G 2200/00 : Waste incineration
• CPC Class Codes: F23G 2202/101 : with controlled oxidant supply
• CPC Class Codes: F23G 2202/103 : in separate chambers
• CPC Class Codes: F23G 2202/50 : in a matrix bed combustion chamber
• CPC Class Codes: F23G 2203/503 : with two or more fluidised beds
• CPC Class Codes: F23G 2206/10 : reintroducing the heat in the same process, e.g. for predrying
• CPC Class Codes: F23G 5/006 : General arrangement of incineration plant, e.g. flow sheets
• CPC Class Codes: F23G 5/30 : having a fluidised bed
• CPC Class Codes: Y02E 20/16 : Combined cycle power plant [CCPP], or combined cycle gas turbine [CCGT]
• CPC Class Codes: Y02E 50/30 : Fuel from waste, e.g. synthetic alcohol or diesel

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.

Claims

1. A two-stage 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), said second reactor char input (204) being 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 the second interior (201);

(c) 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); and

(d) 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);

wherein;

the second reactor heat exchanger (HX-B) comprises;

a second reactor heat transfer medium inlet (212) configured to receive a heat transfer medium (210) at a second reactor inlet temperature (TI); and

a second reactor heat transfer medium outlet (216) configured to output the heat transfer medium (210), at a higher, second reactor outlet temperature (T2);

the first reactor reactant input (108) is in fluid communication with the second reactor heat transfer medium outlet (216) and is configured to introduce at least a portion of said heat transfer medium (210) into the first interior (101) as a reactant (106) of the first reactor (100);

the first reactor is operated at a first reactor pressure; and

the second reactor is operated at a second reactor pressure, the first reactor pressure being greater than the second reactor pressure.

2. The two-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 of said heat transfer medium (210) into the second interior (201) as a reactant of the second reactor (200).

3. The two-stage product gas generation system (1001) according to claim 1, further comprising:

a first reactor oxygen-containing gas input (120) to the first interior (101) and configured to receive a first reactor oxygen-containing gas (118).

4. The two-stage product gas generation system (1001) according to claim 1, 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).

5. The two-stage 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.

6. The two-stage product gas generation system (1001) according to claim 5, further comprising:

a first reactor dense-bed zone reactant input (108A) configured to receive a first reactor dense-bed zone reactant (106A) into the first reactor dense bed zone;

a first reactor feed zone reactant input (108B) configured to receive a first reactor feed zone reactant (106B) into the first reactor feed zone; and

a first reactor splash zone reactant input (108C) configured to receive a first reactor splash zone reactant (106C) into the first reactor splash zone.

7. The two-stage product gas generation system (1001) according to claim 6, further comprising:

at least three first reactor feed zone reactant inputs; and

at least three first reactor splash zone reactant inputs.

8. The two-stage product gas generation system (1001) according to claim 5, further comprising:

a first reactor dense-bed zone oxygen-containing gas input (120A) configured to receive a first reactor oxygen-containing gas (118A) into the first reactor dense-bed zone;

a first reactor feed zone oxygen-containing gas input (120B) configured to receive a first reactor feed zone oxygen-containing gas (118B into the first reactor feed zone; and

a first reactor splash zone oxygen-containing gas input (120C) configured to receive a first reactor splash zone oxygen-containing gas (118C) into the first reactor splash zone.

9. The two-stage product gas generation system (1001) according to claim 8, comprising:

at least three first reactor feed zone oxygen-containing gas inputs; and

at least three first reactor splash zone oxygen-containing gas inputs.

10. The two-stage 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.

11. The two-stage product gas generation system (1001) according to claim 10, further comprising:

a second reactor dense-bed zone reactant input (208A) configured to receive a second reactor dense-bed zone reactant (206A) into the second reactor dense-bed zone;

a second reactor feed zone reactant input (208B) configured to receive a second reactor feed zone reactant (206B) into the second reactor feed zone; and

a second reactor splash zone reactant input (208C) configured to receive a second reactor splash zone reactant (206C) into the second reactor splash zone.

12. The two-stage product gas generation system (1001) according to claim 11, further comprising:

a second reactor dense-bed zone oxygen-containing gas input (220A) configured to receive a second reactor oxygen-containing gas (218A) into the second reactor dense-bed zone;

a second reactor feed zone oxygen-containing gas input (220B) configured to receive a second reactor feed zone oxygen-containing gas (218B into the second reactor feed zone; and

a second reactor splash zone oxygen-containing gas input (220C) configured to receive a second reactor splash zone oxygen-containing gas (218C) into the second reactor splash zone.

13. The two-stage product gas generation system (1001) according to claim 12, comprising:

at least three second reactor feed zone oxygen-containing gas inputs; and

at least three second reactor splash zone oxygen-containing gas inputs.

14. The two-stage product gas generation system (1001) according to claim 13, comprising:

at least three second reactor feed zone reactant inputs; and

at least three second reactor splash zone reactant inputs.

15. The two-stage product gas generation system (1001) according to claim 1, further comprising:

a second reactor solids output (207); and

a first reactor solids input (107) in fluid communication with the second reactor solids output (207), wherein;

the first reactor solids input (107) is configured to receive, into the first interior (101), second reactor particulate heat transfer material (205) present in the second interior (201).

16. The two-stage product gas generation system (1001) according to claim 1, wherein the first reactor further comprises:

a first reactor first heat exchanger (HX-A1) in thermal contact with the first interior (101), the first reactor first heat exchanger (HX-A1) comprising;

a first reactor first heat exchanger fuel inlet (112A) configured to receive a first reactor first heat exchanger fuel (110A) at a first inlet temperature (T3A); and

a first reactor first heat exchanger combustion stream outlet (116A) configured to output a first reactor first heat exchanger combustion stream (114A), at a first outlet temperature (T4A).

17. The two-stage product gas generation system (1001) according to claim 16, further comprising:

an auxiliary heat exchanger (HX-2) external to the first reactor (100) and in thermal contact with the first reactor first heat exchanger combustion stream (114A) exiting the first reactor first heat exchanger combustion stream outlet (116A);

wherein

the auxiliary heat exchanger (HX-2) is configured to transfer heat from the first reactor first heat exchanger combustion stream (114A) to an auxiliary heat exchanger heat transfer medium (164) which exits the auxiliary heat exchanger (HX-2) via auxiliary heat exchanger heat transfer medium outlet conduit (170).

18. The two-stage product gas generation system (1001) according to claim 17, wherein:

the auxiliary heat exchanger heat transfer medium outlet conduit (170) is in fluid communication with the first reactor reactant input (108) of the first reactor (100), to thereby supply the auxiliary heat exchanger heat transfer medium (164) as a reactant to the first reactor (100).

19. The two-stage product gas generation system (1001) according to claim 17, wherein:

the auxiliary heat exchanger heat transfer medium outlet conduit (170) is in fluid communication with the second reactor heat transfer medium inlet (212), to thereby supply the auxiliary heat exchanger heat transfer medium (164) to the second reactor heat exchanger (HX-B).

20. The two-stage product gas generation system (1001) according to claim 16, wherein the first reactor comprises:

two first reactor heat exchangers (HX-A1, HX-A2) positioned in the first interior (101) and vertically spaced apart from one another along a first height dimension of the first interior;

wherein;

alternate first reactor heat exchangers along said first height dimension are arranged cross-wise to one another such that, in a top view of the first interior, the four first reactor heat exchangers define four open vertically extending quadrants (Q1, Q2, Q3, Q4).

21. The two-stage product gas generation system (1001) according to claim 20, comprising:

six first reactor carbonaceous material inputs (104A-104F) to the first interior (101);

wherein;

only two of the six first reactor carbonaceous material inputs are configured to inject carbonaceous material into the vertically extending quadrants (Q1, Q2, Q3, Q4).

22. The two-stage product gas generation system (1001) according to claim 16, further comprising:

a front tubesheet heat exchanger (HX-A1 Al) in thermal contact with the first reactor (100) and comprising;

a front tubesheet heat transfer medium inlet (AF1), and a front tubesheet heat transfer medium outlet (AF2) in fluid communication with the front tubesheet heat transfer medium inlet (AF1).

23. The two-stage product gas generation system (1001) according to claim 22, further comprising:

a rear tubesheet heat exchanger (HX-A1 A2) in thermal contact with the first reactor (100), and comprising;

a rear tubesheet heat transfer medium inlet (AR1), and a rear tubesheet heat transfer medium outlet (AR2) in fluid communication with rear tubesheet heat transfer medium inlet (AR1).

24. The two-stage product gas generation system (1001) according to claim 23, wherein:

the front tubesheet heat transfer medium outlet (AF2) and the rear tubesheet heat transfer medium outlet (AR2) are both in fluid communication with the second reactor heat transfer medium inlet (212), such that;

at least a portion of fluid exiting the front tubesheet heat transfer medium outlet (AF2) and the rear tubesheet heat transfer medium outlet (AR2) is provided as at least a portion of said heat transfer medium (210) at the second reactor heat transfer medium inlet (212).

25. The two-stage product gas generation system (1001) according to claim 24, further comprising a steam drum (425) having:

one or more inlets in fluid communication with the front tubesheet heat transfer medium outlet (AF2) and the rear tubesheet heat transfer medium outlet (AR2); and

one or more outlets in fluid communication with the second reactor heat transfer medium inlet (212).

26. The two-stage product gas generation system (1001) according to claim 25, wherein:

a portion of the front tubesheet heat transfer medium (AF) entering the front tubesheet heat transfer medium inlet (AF1) in liquid phase exits the front tubesheet heat transfer medium outlet (AF2) as a first vapor phase;

a portion of the rear tubesheet heat transfer medium (AR) entering the rear tubesheet heat transfer medium inlet (AR1) in liquid phase exits the rear tubesheet heat transfer medium outlet (AR2) as a second vapor phase; and

the first and second vapor phases enter said steam drum (425).

27. The two-stage product gas generation system (1001) according to claim 1, wherein:

the heat transfer medium (210) received by said second reactor heat transfer medium inlet (212) at said second reactor inlet temperature (T1) is provided by a downstream heat exchanger associated with a primary gas clean-up system configured to clean up said product gas.

28. A two-stage 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) provided with a first dense-bed zone (AZ-A), a first feed zone (AZ-B) above the first dense-bed zone , and a first splash zone (AZ-C) above the first feed zone, the first reactor further comprising;

a first reactor dense-bed zone reactant input (108A) to the first dense-bed zone (AZ-A);

a first reactor feed zone reactant input (108B) to the first feed zone (AZ-B);

a first reactor splash zone reactant input (108C) to the first splash zone (AZ-C);

a first reactor carbonaceous material input (104) to the first feed zone (AZ-B); and

a first reactor product gas output (124); and

(b) a second reactor (200) having a second interior (201) provided with a second dense-bed zone (BZ-A), second feed zone (BZ-B) above the second dense-bed zone, and a second splash zone (BZ-C) above the second feed zone, the second reactor further comprising;

a second reactor char input (204) to the second feed zone (BZ-B), said second reactor char input (204) being in fluid communication with the first reactor product gas output (124);

a second reactor dense-bed zone reactant input (208A) to the second dense-bed zone (BZ-A);

a second reactor feed zone reactant input (208B) to the second feed zone (BZ-B);

a second reactor splash zone reactant input (208C) to the second splash zone (BZ-C);

a second reactor dense-bed zone oxygen-containing gas input (220A) to the second dense-bed zone (BZ-A);

a second reactor feed zone oxygen-containing gas input (220B) to the second feed zone (BZ-B);

a second reactor splash zone oxygen-containing gas input (220C) to the second splash zone (BZ-C);

a second reactor product gas output (224); and

a second reactor heat exchanger (HX-B) in thermal contact with the second interior (201);

wherein;

the second reactor heat exchanger (HX-B) is configured to receive a heat transfer medium (210) at a second reactor inlet temperature (T1) and output the heat transfer medium (210), at a higher, second reactor outlet temperature (T2), via a second reactor heat transfer medium outlet (216); and

the second reactor heat transfer medium outlet (216) is configured to be selectively in fluid communication with any combination of the first reactor dense-bed zone reactant input (108A), the first reactor feed zone reactant input (108B) and the first reactor splash zone reactant input (108C);

whereby;

at least a portion of the heat transfer medium (210) is capable of being introduced into any combination of;

(i) the corresponding first reactor dense-bed zone (AZ-A),

(ii) the first reactor feed zone (AZ-B), and

(iii) the first reactor splash zone (AZ-C).

29. The two-stage product gas generation system (1001) according to claim 28, wherein the first reactor (100) further comprises:

a first reactor dense-bed oxygen-containing gas input (120A) selectively in fluid communication with an oxygen-containing gas;

a first reactor feed zone oxygen-containing gas input (120B) selectively in fluid communication with an oxygen-containing gas; and

a first reactor splash zone oxygen-containing gas input (120C) selectively in fluid communication with an oxygen-containing gas.

30. The two-stage product gas generation system (1001) according to claim 29, wherein the first reactor comprises:

at least three first reactor feed zone oxygen-containing gas inputs (AZB2,AZB3,AZB4); and

at least three first reactor splash zone oxygen-containing gas inputs (AZC2,AZC3,AZC4).