SYSTEM AND METHOD FOR PROCESSING MATERIAL TO GENERATE SYNGAS USING WATER INJECTION

• US 20120018294A1
• Filed: 10/28/2010
• Published: 01/26/2012
• Est. Priority Date: 07/21/2010
• Status: Active Grant

• Current Assignee: Responsible Energy Inc.
• Original Assignee: Responsible Energy Inc.
• Inventors: Houze, Graham Campbell, Jensen, Robert Christian
• Granted Patent: US 9,080,116 B2
• Time in Patent Office: Days
• US Class Current: 204/164
• CPC Class Codes: C10J 2200/12 Electrodes present in the gasifier
• CPC Class Codes: C10J 2200/158 Screws
• CPC Class Codes: C10J 2300/0906 Physical processes, e.g. shredding, comminuting, chopping, sorting
• CPC Class Codes: C10J 2300/0973 Water
• CPC Class Codes: C10J 2300/1238 by plasma
• CPC Class Codes: C10J 3/18 using electricity
• CPC Class Codes: C10J 3/30 Fuel charging devices
• CPC Class Codes: C10J 3/32 Devices for distributing fuel evenly over the bed or for stirring up the fuel bed
• CPC Class Codes: C10J 3/726 Start-up
• CPC Class Codes: C10K 1/04 by cooling to condense non-gaseous materials C10K1/001 takes precedence

Abstract

The present invention is directed to system and method for processing material to generate syngas. A reactor chamber is implemented with a plurality of electrodes that can generate an arc within the chamber when electricity is applied to them. The arc can be used to create free radicals which along with the heat and light of the arc breakdown material comprising carbonaceous material, such as Municipal Solid Waste (MSW), into gas components that form syngas. The syngas can be extracted from the reactor chamber and be used for various commercial purposes. The reactor chamber may comprise a material feed system operable to move material from a material input opening in the reactor chamber towards the electrodes at a controlled rate. Further, the reactor chamber may comprise a water injection system within the reactor chamber operable to inject water into the reactor chamber while electricity is applied to the electrodes. Yet further, the reactor chamber may comprise a gas removal system within the reactor chamber operable to extract gas generated from breakdown of the material from a plurality of gas removal locations. The gas removal system may be integrated within the material feed system.

Claims

1. A system comprising:

a reactor chamber operable to receive material;

a plurality of electrodes at least partially protruding into the reactor chamber, the electrodes operable to generate an arc within the reactor chamber when electricity is applied to them;

a water injection system within the reactor chamber operable to inject water into the reactor chamber while electricity is applied to the electrodes; and

a gas removal system within the reactor chamber operable to extract gas generated from breakdown of the material.

2. A system according to claim 1, wherein the water injection system is operable to inject water proximate to the plurality of electrodes.

3. A system according to claim 1, wherein the water injection system is operable to inject water into the reactor chamber at a controlled rate.

4. A system according to claim 3 further comprising a control system operable to control the rate at which water is injected into the reactor chamber by the water injection system based upon a monitored aspect of the gas extracted by the gas removal system.

5. A system according to claim 4, wherein the monitored aspect of the gas comprises a level of moisture within the gas extracted by the gas removal system;

and wherein the control system is operable to control the rate of injection of water into the reactor chamber by the water injection system in response to the level of moisture within the extracted gas.

6. A system according to claim 4, wherein the monitored aspect of the gas comprises a level of one or more contaminants within the gas extracted by the gas removal system;

and wherein the control system is operable to control the rate of injection of water into the reactor chamber by the water injection system in response to the level of the one or more contaminants within the extracted gas.

7. A system according to claim 4, wherein the monitored aspect of the gas comprises a level of one or more component parts of syngas within the gas extracted by the gas removal system;

and wherein the control system is operable to control the rate of injection of water into the reactor chamber by the water injection system in response to the level of the one or more component parts of syngas within the extracted gas.

8. A system according to claim 1 further comprising a material feed system within the reactor chamber operable to move material from a material input opening within the reactor chamber towards the electrodes.

9. A system according to claim 8, wherein the water injection system is integrated within the material feed system.

10. A system according to claim 9, wherein the material feed system comprises a material feed screw operable to move material from the material input opening towards the electrodes when rotated, the material feed screw comprising a central shaft and at least one flute connected to the central shaft;

wherein the water injection system comprises a water injection pipe integrated within the central shaft of the material feed screw, the water injection pipe protruding out of an end of the material feed screw;

wherein a portion of the water injection pipe that protrudes out of the end of the material feed screw comprises a water injection element.

11. A system according to claim 10, wherein the gas removal system comprises a gas removal pipe integrated within the central shaft of the material feed screw and the water injection pipe is integrated within the gas removal pipe;

wherein at least one of a) the gas removal pipe comprises at least one hole aligned with a vent in the central shaft of the material feed screw and b) the gas removal pipe protrudes out of the end of the material feed screw and a portion of the gas removal pipe that protrudes out of the end of the material feed screw comprises a gas removal element.

12. A system according to claim 1, wherein the water injection system is coupled to a water source operable to heat water that is to be provided to the water injection system.

13. A system according to claim 12, wherein the gas removal system is coupled to a gas containing element operable to hold gas extracted from the reactor chamber;

and wherein at least a portion of the water source is coupled to the gas containing element such that heat from the gas extracted from the reactor chamber heats the water that is to be injected into the reactor chamber.

14. A method for generating gas within a reactor chamber, the reactor chamber comprising a plurality of electrodes at least partially protruding into the reactor chamber, the electrodes operable to generate an arc within the reactor chamber when electricity is applied to them, the method comprising:

causing insertion of material into the reactor chamber, the material comprising carbonaceous material;

causing injection of water into the reactor chamber while electricity is applied to the electrodes; and

causing extraction of gas generated from the breakdown of the material from the reactor chamber.

15. A method according to claim 14, wherein the causing injection of water into the reactor chamber is at a controlled rate.

16. A method according to claim 15 further comprising:

monitoring the gas extracted from the reactor chamber; and

controlling the rate at which water is injected into the reactor chamber based at least partially upon results from the monitoring.

17. A method according to claim 16, wherein the monitoring the gas extracted from the reactor chamber comprises monitoring a level of moisture within the gas extracted from the reactor chamber;

and wherein the controlling the rate at which water is injected into the reactor chamber comprises controlling the rate at which water is injected into the reactor chamber based at least partially upon the level of moisture within the extracted gas.

18. A method according to claim 16, wherein the monitoring the gas extracted from the reactor chamber comprises monitoring a level of one or more contaminants within the gas extracted from the reactor chamber;

and wherein the controlling the rate at which water is injected into the reactor chamber comprises controlling the rate at which water is injected into the reactor chamber based at least partially upon the level of the one or more contaminants within the extracted gas.

19. A method according to claim 16, wherein the monitoring the gas extracted from the reactor chamber comprises monitoring a level of one or more component parts of syngas within the gas extracted from the reactor chamber;

and wherein the controlling the rate at which water is injected into the reactor chamber comprises controlling the rate at which water is injected into the reactor chamber based at least partially upon the level of the one or more component parts of syngas within the extracted gas.

20. A method according to claim 14 further comprising causing heating of the water to be injected into the reactor chamber using the gas extracted from the reactor chamber.