Method and apparatus for treating wastes by gasification

• US 6,455,011 B1
• Filed: 09/09/1999
• Issued: 09/24/2002
• Est. Priority Date: 04/23/1996
• Status: Expired due to Term

• Current Assignee: Ebara Corporation, UBE Industries Limited
• Original Assignee: Ebara Corporation, UBE Industries Limited
• Inventors: Fukuda, Toshio, Fujimura, Hiroyuki, Nagato, Shuichi, Takano, Kazuo, Hirayama, Yoshio, Oshita, Takahiro, Irie, Masaaki, Hirose, Tetsuhisa, Fujinami, Shosaku
• Primary Examiner(s): Knode, Marian C.
• Assistant Examiner(s): NECKEL, ALEXA DOROSHENK
• Application Number:
  US09/392,784
• Time in Patent Office: 1,111 Days
• Field of Search: 422/139, 422/140, 422/147, 422/188, 422/141, 48/61, 48/71, 48/72, 48/73, 48/76, 481/28
• US Class Current: 422/139
• CPC Class Codes: C10G 2300/1003 Waste materials
• CPC Class Codes: C10J 2200/158 Screws
• CPC Class Codes: C10J 2300/0956 Air or oxygen enriched air
• CPC Class Codes: C10J 2300/1606 Combustion processes
• CPC Class Codes: C10J 2300/1631 Ash recycling
• CPC Class Codes: C10J 2300/1668 to urea preparation of urea C07C273/00; to ammonia preparation of ammonia C01C1/0405
• CPC Class Codes: C10J 2300/1693 with storage facilities for intermediate, feed and/or product
• CPC Class Codes: C10J 2300/1807 Recycle loops, e.g. gas, solids, heating medium, water
• CPC Class Codes: C10J 2300/1884 with one stream being synthesis gas
• CPC Class Codes: C10J 3/482 Gasifiers with stationary fluidised bed
• CPC Class Codes: C10J 3/487 Swirling or cyclonic gasifiers
• CPC Class Codes: C10J 3/523 for gasifiers with stationary fluidised bed
• CPC Class Codes: C10J 3/54 Gasification of granular or pulverulent fuels by the Winkler technique, i.e. by fluidisation
• CPC Class Codes: C10J 3/56 Apparatus; Plants
• CPC Class Codes: C10J 3/66 by introducing them into the gasification zone
• CPC Class Codes: C10J 3/721 Multistage gasification, e.g. plural parallel or serial gasification stages
• CPC Class Codes: C10J 3/84 with means for removing dust or tar from the gas
• CPC Class Codes: C10K 1/003 of acid contaminants, e.g. acid gas removal
• CPC Class Codes: C10K 1/004 Sulfur containing contaminants, e.g. hydrogen sulfide
• CPC Class Codes: C10K 1/005 Carbon dioxide
• CPC Class Codes: C10K 1/101 : with water only
• CPC Class Codes: C10K 1/165 : at temperatures below zero degrees Celsius
• CPC Class Codes: C10K 3/003 : Reducing the tar content
• CPC Class Codes: C10K 3/04 : reducing the carbon monoxide content , e.g. water-gas shift [WGS]
• CPC Class Codes: Y10S 48/02 : Slagging producer

Abstract

A method and apparatus for treating wastes by two-stage gasification recovers metals or ash content in the wastes in such a state that they can be recycled, and gases containing carbon monoxide (CO) and hydrogen gas (H₂) for use as synthesis gas for ammonia (NH₃) or production of hydrogen gas. The wastes are gasified in a fluidized-bed reactor at a low temperature. Then, gaseous material and char produced in the fluidized-bed reactor are introduced into a high-temperature combustor, and gasified at a high temperature and ash content is converted into molten slag. After water scrubbing and a CO conversion reaction, the gas is separated into H₂ and residual gas. The residual gas is then supplied to the fluidized-bed reactor as a fluidizing gas.

Claims

1. An apparatus for treating at least one waste selected from a group consisting of municipal wastes, plastic wastes including automobile wastes, biomass wastes, and refuse-derived fuel, said apparatus comprising:

a fluidized bed reactor for partially combusting the wastes at a temperature of from 450°

C. to 950°

C., thereby forming a gaseous material and carbonous material, while crushing the carbonous material by a fluidized bed in said fluidized bed reactor to thereby form char, said fluidized bed reactor having an outlet for discharge of the gaseous material and the char;

a combustor, separate from said fluidized bed reactor and operable at a temperature sufficient to melt an ash content in the char, for receiving the gaseous material and the char from said outlet of said fluidized bed reactor and for gasifying the gaseous material and the char to form synthesis gas, while melting the ash content to thereby form molten slag, said combustor having an outlet for discharge of the molten slag;

a quencher to quench the synthesis gas received from said combustor to form quenched synthesis gas and to generate steam;

a CO converter to receive the cooled synthesis gas and steam and to perform a CO conversion reaction to produce H₂ and residual gas;

a separator to separate the H₂ from the residual gas; and

a passage to supply the residual gas to said fluidized bed reactor as fluidizing gas for fluidizing the fluidized bed therein.

2. An apparatus as claimed in claim 1, wherein said fluidized bed reactor is operable to partially combust the wastes at a temperature of from 450°

C. to 650°

C.

3. An apparatus as claimed in claim 1, further comprising a device to remove hydrogen chloride from the cooled synthesis gas and steam.

4. An apparatus as claimed in claim 3, wherein said device comprises a scrubber.

5. An apparatus as claimed in claim 1, wherein said separator comprises a pressure swing adsorption separator or a hydrogen gas separating membrane separator.

6. An apparatus as claimed in claim 1, wherein said combustor comprises a swirling combustor.

7. An apparatus as claimed in claim 1, wherein said fluidized bed reactor comprises a revolving flow fluidized bed reactor.

8. An apparatus as claimed in claim 1, wherein said fluidized bed reactor and said combustor are operable at a pressure of from 5 to 90 atm.

9. An apparatus as claimed in claim 1, wherein said temperature at which said combustor is operable comprises at least 1200°

C.

10. An apparatus as claimed in claim 1, further comprising means to add a supplemental fuel to the at least one waste sufficient to ensure an average lower calorific value thereof of at least 3500 kcal/kg.

11. An apparatus as claimed in claim 1, further comprising means to add oxygen or a mixture of oxygen and steam to said fluidized bed reactor as a gasifying agent.

12. An apparatus as claimed in claim 1, further comprising means to add oxygen, a mixture of oxygen and steam or a mixture of oxygen and carbon dioxide to said combustor as a gasifying agent.

13. An apparatus as claimed in claim 1, further comprising means to add oxygen, air or a mixture of oxygen , air and steam to said fluidized bed reactor as a gasifying agent, and to add oxygen or a mixture of oxygen and steam to said combustor as a gasifying agent, such that said synthesis gas contains CO, H₂ and N₂, and such that a molar ratio of the sum of CO and H₂ to N₂ is approximately 3.

14. An apparatus as claimed in claim 1, further comprising means to add a total amount of oxygen as a gasifying agent to said fluidized bed reactor and said combustor equal to 0.1 to 0.6 of the theoretical amount of oxygen required for combustion of the wastes.

15. An apparatus as claimed in claim 1, further comprising means to add an amount of oxygen as a gasifying agent to said fluidized bed reactor equal to 0.1 to 0.3 of the theoretical amount of oxygen required for combustion of the wastes.

16. An apparatus as claimed in claim 1, wherein the fluidized bed in said fluidized bed reactor comprises at least one of sand, alumina, iron granules, and dolomite.

17. An apparatus as claimed in claim 1, wherein said fluidized bed reactor includes a freeboard above said fluidized bed, and said fluidized bed reactor is operable to conduct the partial combusting of the wastes within said fluidized bed and said freeboard.

18. An apparatus as claimed in claim 1, wherein said quencher is operable to remove the molten slag and cool the synthesis gas by contacting the synthesis gas and molten slag with water.

19. An apparatus as claimed in claim 18, wherein said combustor includes a gasifying chamber within which the gasifying is conducted and a cooling chamber containing said quencher.