Methods and Apparatus for Solid Carbonaceous Materials Synthesis Gas Generation

• US 20090119994A1
• Filed: 10/06/2008
• Published: 05/14/2009
• Est. Priority Date: 04/11/2006
• Status: Active Grant

• Current Assignee: Thermo Technologies LLC (Thermo Fisher Scientific Incorporated)
• Original Assignee: Thermo Technologies LLC (Thermo Fisher Scientific Incorporated)
• Inventors: Abramov, Grigori A., Kleinke, Richard A., Johnson, Dennis E.J., Wiley, Marcus A.
• Granted Patent: US 8,017,041 B2
• Time in Patent Office: Days
• US Class Current: 48/62.R
• CPC Class Codes: C02F 1/32 with ultraviolet light
• CPC Class Codes: C10B 1/10 Rotary retorts
• CPC Class Codes: C10J 2300/0903 Feed preparation
• CPC Class Codes: C10J 2300/0916 Biomass
• CPC Class Codes: C10J 2300/093 Coal
• CPC Class Codes: C10J 2300/0943 Coke
• CPC Class Codes: C10J 2300/0946 Waste, e.g. MSW, tires, glass, tar sand, peat, paper, lignite, oil shale
• CPC Class Codes: C10J 2300/1215 using synthesis gas as fuel
• CPC Class Codes: C10J 3/66 by introducing them into the gasification zone
• CPC Class Codes: C10K 1/101 with water only
• CPC Class Codes: Y02E 20/18 Integrated gasification combined cycle [IGCC], e.g. combined with carbon capture and storage [CCS]
• CPC Class Codes: Y02E 50/10 Biofuels, e.g. bio-diesel
• CPC Class Codes: Y02E 50/30 Fuel from waste, e.g. synthetic alcohol or diesel
• CPC Class Codes: Y02P 20/145 the feedstock being materials of biological origin

Abstract

Methods and apparatus may permit the generation of consistent output synthesis gas from highly variable input feedstock solids carbonaceous materials. A stoichiometric objectivistic chemic environment may be established to stoichiometrically control carbon content in a solid carbonaceous materials gasifier system. Processing of carbonaceous materials may include dominative pyrolytic decomposition and multiple coil carbonaceous reformation. Dynamically adjustable process determinative parameters may be utilized to refine processing, including process utilization of negatively electrostatically enhanced water species, process utilization of flue gas (9), and adjustment of process flow rate characteristics. Recycling may be employed for internal reuse of process materials, including recycled negatively electrostatically enhanced water species, recycled flue gas (9), and recycled contaminants. Synthesis gas generation may involve predetermining a desired synthesis gas for output and creating high yields of such a predetermined desired synthesis gas.

Claims

1-512. -512. (canceled)

513. A gasifier system comprising:

a carbonaceous feedstock input;

a gasifier process flow path originating at said carbonaceous feedstock input and routed through said gasifier system;

at least one pressurization system joined to at least a portion of said gasifier process flow path;

at least one heater system joined to at least a portion of said gasifier process flow path;

a carbonaceous materials pyrolysis chamber through which said gasifier process flow path is routed;

a mechanical gasifier drive system active within at least a portion of said carbonaceous materials pyrolysis chamber;

at least one mechanically propelled carbonaceous materials pyrolysis decomposition platform responsive to said mechanical gasifier drive system;

at least one mechanically propelled pyrolytically decomposed carbonaceous materials processor platform responsive to said mechanical gasifier drive system;

a select product gas output located at a terminus of said gasifier process flow path routed through said gasifier system.

514-658. -658. (canceled)

659. A method for select synthesis gas generation from carbonaceous materials comprising the steps of:

inputting a carbonaceous feedstock;

subjecting said carbonaceous feedstock to a pressurized environment;

increasing a temperature within said pressurized environment to which said carbonaceous feedstock is subjected;

mechanically propelling at least one carbonaceous materials pyrolysis decomposition platform in a gasifier system;

pyrolytically decomposing said carbonaceous feedstock in said gasifier system on said carbonaceous materials pyrolysis decomposition platform;

mechanically propelling at least one pyrolytically decomposed carbonaceous materials processor platform in said gasifier system;

carbonaceously reforming pyrolytically decomposed carbonaceous material in said gasifier system on said pyrolytically decomposed carbonaceous materials processor platform;

generating at least some components of a select product gas in response to said steps of processing; and

outputting at least some select product gas from said gasifier system.

660. A method for select synthesis gas generation from carbonaceous materials as described in claim 659 wherein the step of inputting a carbonaceous feedstock comprises the step of inputting a feedstock solids carbonaceous material, and wherein the step of pyrolytically decomposing said carbonaceous feedstock in said gasifier system on said carbonaceous materials pyrolysis decomposition platform comprises the step of pyrolytically decomposing said feedstock solids carbonaceous material in said gasifier system on said carbonaceous materials pyrolysis decomposition platform, and wherein the step of processing pyrolytically decomposed carbonaceous material in said gasifier system comprises the step of processing pyrolytically decomposed carbonaceous material in said gasifier system.

661. A method for select synthesis gas generation from carbonaceous materials as described in claim 660 wherein the step of mechanically propelling a carbonaceous materials pyrolysis decomposition platform in a gasifier system comprises the step of rotating a carbonaceous materials pyrolysis decomposition platform in a gasifier system, and wherein the step of mechanically propelling a carbonaceous materials pyrolysis decomposition platform in a gasifier system comprises the step of mechanically rotating a pyrolytically decomposed carbonaceous materials processor platform in said gasifier system.

662. A method for select synthesis gas generation from carbonaceous materials as described in claim 661 wherein the step of mechanically propelling a carbonaceous materials pyrolysis decomposition platform in a gasifier system and the step of mechanically propelling a pyrolytically decomposed carbonaceous materials processor platform in said gasifier system comprises the step of horizontally rotating said platforms.

663. A method for select synthesis gas generation from carbonaceous materials as described in claim 660 or 662 wherein the step of mechanically propelling a carbonaceous materials pyrolysis decomposition platform in a gasifier system and the step of mechanically propelling a pyrolytically decomposed carbonaceous materials processor platform in said gasifier system comprises the step of coordinatively mechanically propelling at least said first said second propelled platforms.

664. A method for select synthesis gas generation from carbonaceous materials as described in claim 663 wherein the step of coordinatively mechanically propelling at least said first and said second propelled platforms comprise the step of synchronously mechanically propelling at least said first and said second propelled platforms.

665. A method for select synthesis gas generation from carbonaceous materials as described in claim 663 wherein the step of mechanically propelling a carbonaceous materials pyrolysis decomposition platform in a gasifier system and the step of mechanically propelling a pyrolytically decomposed carbonaceous materials processor platform in said gasifier system comprises the step of singularly driving said first and said second propelled platforms.

666. A method for select synthesis gas generation from carbonaceous materials as described in claim 659 wherein the step of mechanically propelling a carbonaceous materials pyrolysis decomposition platform in a gasifier system and the step of mechanically propelling a pyrolytically decomposed carbonaceous materials processor platform in said gasifier system comprises the steps of:

mechanically propelling a carbonaceous materials pyrolysis carousel in said gasifier system; and

mechanically propelling a pyrolytically decomposed carbonaceous materials processor carousel in said gasifier system.

667. A method for select synthesis gas generation from carbonaceous materials as described in claim 666 wherein the step of mechanically propelling a carbonaceous materials pyrolysis carousel in said gasifier system and the step of mechanically propelling a pyrolytically decomposed carbonaceous materials processor carousel in said gasifier system comprises the step of mechanically propelling a tiered carousel in said gasifier system.

668. A method for select synthesis gas generation from carbonaceous materials as described in claim 667 wherein the step of increasing a temperature within said pressurized environment to which said carbonaceous feedstock is subjected comprises the step of:

burning product synthesis gas at a bottom location within said gasifier system; and

effecting a tiered heat distribution within said gasifier system having increasing temperature at lower levels.

669. A method for select synthesis gas generation from carbonaceous materials as described in claim 668 wherein the step of mechanically propelling a carbonaceous materials pyrolysis decomposition platform in a gasifier system and the step of mechanically propelling a pyrolytically decomposed carbonaceous materials processor platform in said gasifier system comprises the step of singularly driving both said mechanically propelled platforms.

670. A method for select synthesis gas generation from carbonaceous materials as described in claim 661 and further comprising the step of thermally encasing said gasifier processes in a thermal circumscribing encasement, and wherein the step of mechanically propelling a carbonaceous materials pyrolysis decomposition platform in a gasifier system comprises the step of sealably encased mechanically propelling a carbonaceous materials pyrolysis decomposition platform in a gasifier system, and wherein the step of pyrolytically decomposing said carbonaceous feedstock in said gasifier system on said carbonaceous materials pyrolysis decomposition platform comprises the step of sealably encased pyrolytically decomposing said carbonaceous feedstock in said gasifier system on said carbonaceous materials pyrolysis decomposition platform, and wherein the step of mechanically propelling a pyrolytically decomposed carbonaceous materials processor platform in said gasifier system comprises the step of sealably encased mechanically propelling a pyrolytically decomposed carbonaceous materials processor platform in said gasifier system, and wherein the step of carbonaceous reforming pyrolytically decomposed carbonaceous material in said gasifier system on said pyrolytically decomposed carbonaceous materials processor platform comprises the step of sealably encased carbonaceous reforming pyrolytically decomposed carbonaceous material in said gasifier system on said pyrolytically decomposed carbonaceous materials processor platform, and wherein the step of generating at least some components of a select product gas in response to said steps of processing comprises the step of sealably encased generating at least some components of a select product gas in response to said steps of processing.

671. A method for select synthesis gas generation from carbonaceous materials as described in claim 670 wherein the step of increasing a temperature within said pressurized environment to which said carbonaceous feedstock is subjected comprises the step of:

burning product synthesis gas at a bottom location within said gasifier system; and

effecting a tiered heat distribution within said gasifier system having increasing temperature at lower levels.

672. A method for select synthesis gas generation from carbonaceous materials as described in claim 671 wherein the step of mechanically propelling a carbonaceous materials pyrolysis decomposition platform in a gasifier system comprises the step of coaxially propelling said carbonaceous materials pyrolysis decomposition platform and said pyrolytically decomposed carbonaceous materials processor platform.

673. A method for select synthesis gas generation from carbonaceous materials as described in claim 672 wherein the step of inputting a carbonaceous feedstock comprises the step of offcenter inputting said carbonaceous feedstock to said thermal circumscribing encasement.

674. A method for select synthesis gas generation from carbonaceous materials as described in claim 660, 666, or 673 wherein the step of pyrolytically decomposing said feedstock solids carbonaceous material in said gasifier system on said carbonaceous materials pyrolysis decomposition platform comprises the step of pluraly pyrolytically decomposing said feedstock solids carbonaceous material in said gasifier system on a plurality of carbonaceous materials pyrolysis decomposition platforms.

675. A method for select synthesis gas generation from carbonaceous materials as described in claim 674 wherein the step of pluraly pyrolytically decomposing said feedstock solids carbonaceous material in said gasifier system on a plurality of carbonaceous materials pyrolysis decomposition platforms comprise the step of establishing a plurality of pyrolytic output coordinated carbonaceous materials pyrolysis decomposition platforms.

676. A method for select synthesis gas generation from carbonaceous materials as described in claim 675 wherein the step of establishing a plurality of pyrolytic output coordinated carbonaceous materials pyrolysis decomposition platforms and further comprising the step of sequentially pyrolytically decomposing said feedstock solids carbonaceous material on a plurality of carbonaceous materials pyrolysis decomposition platforms.

677. A method for select synthesis gas generation from carbonaceous materials as described in claim 676 wherein the step of sequentially pyrolytically decomposing said feedstock solids carbonaceous material on a plurality of carbonaceous materials pyrolysis decomposition platforms comprise the steps of:

first pyrolytically decomposing said feedstock solids carbonaceous material on a first carbonaceous materials pyrolysis decomposition platform; and

second pyrolytically decomposing said feedstock solids carbonaceous material on a second carbonaceous materials pyrolysis decomposition platform.

678. A method for select synthesis gas generation from carbonaceous materials as described in claim 677 wherein the step of first pyrolytically decomposing said feedstock solids carbonaceous material on a first carbonaceous materials pyrolysis decomposition platform and the step of a second pyrolytically decomposing said feedstock solids carbonaceous material on a second carbonaceous materials pyrolysis decomposition platform comprise the step of differentiated pyrolytically decomposing on each of said platforms in pyrolysis environments differentiated by a process factor variable selected from a group consisting of:

a process material size factor, a process temperature factor, a process duration factor, a differentiated environment factor, a reactor electrostatic steam factor, a chemic environment factor, a water environment factor, a negative electrostatic charge water environment factor, a differentiated carbon content factor, a differentiated oxygen content factor, a differentiated flue gas content factor, a differentiated product gas factor, and a recycled process material factor.

679. A method for select synthesis gas generation from carbonaceous materials as described in claim 674 wherein the step of carbonaceously reforming pyrolytically decomposed carbonaceous material in said gasifier system on said pyrolytically decomposed carbonaceous materials processor platform comprises the step of pluraly carbonaceously reforming said pyrolytically decomposed carbonaceous material in said gasifier system on a plurality of pyrolytically decomposed carbonaceous material carbonaceous reformation platforms.

680. A method for select synthesis gas generation from carbonaceous materials as described in claim 679 wherein the step of pluraly carbonaceously reforming said pyrolytically decomposed carbonaceous material in said gasifier system on a plurality of pyrolytically decomposed carbonaceous material reformation platforms comprises the step of establishing a plurality of carbonaceous reformation output coordinated pyrolytically decomposed carbonaceous material reformation platforms.

681. A method for select synthesis gas generation from carbonaceous materials as described in claim 680 wherein the step of establishing a plurality of reformation output coordinated pyrolytically decomposed carbonaceous material reformation platforms comprises the step of sequentially reforming said pyrolytically decomposed carbonaceous material on a plurality of pyrolytically decomposed carbonaceous material reformation platforms.

682. A method for select synthesis gas generation from carbonaceous materials as described in claim 681 wherein the step of sequentially carbonaceously reforming said pyrolytically decomposed carbonaceous material on a plurality of pyrolytically decomposed carbonaceous material reformation platforms comprises the steps of:

first carbonaceously reforming said pyrolytically decomposed carbonaceous material on a first pyrolytically decomposed carbonaceous material reformation platform; and

second carbonaceously reforming said pyrolytically decomposed carbonaceous material on a second pyrolytically decomposed carbonaceous material reformation platform.

683. A method for select synthesis gas generation from carbonaceous materials as described in claim 682 wherein the step of first carbonaceously reforming said pyrolytically decomposed carbonaceous material on a first pyrolytically decomposed carbonaceous material reformation platform and the step of second carbonaceously reforming said pyrolytically decomposed carbonaceous material on a second pyrolytically decomposed carbonaceous material reformation platform comprise the step of differentiated reformation processing on each of said platforms in carbonaceous reformation environments differentiated by a process factor variable selected from a group consisting of:

a process material size factor, a process temperature factor, a process duration factor, a differentiated environment factor, a reactor electrostatic steam factor, a chemic environment factor, a water environment factor, a negative electrostatic charge water environment factor, a differentiated carbon content factor, a differentiated oxygen content factor, a differentiated flue gas content factor, a differentiated product gas factor, and a recycled process material factor.

684. A method for select synthesis gas generation from carbonaceous materials as described in claim 660, 662, 666, or 670 and further comprising the step of transferring processed material between processes within said gasifier system.

685. A method for select synthesis gas generation from carbonaceous materials as described in claim 684 wherein the step of transferring processed material between processes within said gasifier system comprises the step of gravimetrically transferring said processed material between processes within said gasifier system.

686. A method for select synthesis gas generation from carbonaceous materials as described in claim 685 wherein the step of gravimetrically transferring said processed material between processes within said gasifier system comprises the step of dispersionary freefall transferring said processed material between processes within said gasifier system.

687. A method for select synthesis gas generation from carbonaceous materials as described in claim 686 wherein the step of dispersionary freefall transferring said processed material between processes within said gasifier system comprises the step of fixed element scraping said processed material to effect a transfer of said processed material between processes within said gasifier system.

688. A method for select synthesis gas generation from carbonaceous materials as described in claim 666 and further comprising the step of sidewall injecting a negative electrostatically enhanced water species within said gasifier system.

689. A method for select synthesis gas generation from carbonaceous materials as described in claim 688 and further comprising the step of driveshaft injecting a negative electrostatically enhanced water species within said gasifier system.

690. A method for select synthesis gas generation from carbonaceous materials as described in claim 689 and further comprising the step of disbursing said negative electrostatically enhanced water species from a vicinity of said driveshaft to within said gasifier system.

691. A method for select synthesis gas generation from carbonaceous materials as described in claim 660 wherein the step of inputting a feedstock solids carbonaceous material comprises the step of dispersively propelling a feedstock solids carbonaceous material for processing within said gasifier system.

692. A method for select synthesis gas generation from carbonaceous materials as described in claim 691 wherein the step of dispersively propelling a feedstock solids carbonaceous material for processing within said gasifier system comprises the step of pneumatically propelling said feedstock solids carbonaceous material for processing within said gasifier system.

693. A method for select synthesis gas generation from carbonaceous materials as described in claim 691 or 692 wherein the step of dispersively propelling a feedstock solids carbonaceous material for processing within said gasifier system and further comprises the step of feedstock energy accretively propelling said feedstock solids carbonaceous material for processing within said gasifier system.

694. A method for select synthesis gas generation from carbonaceous materials as described in claim 693 wherein the step of feedstock energy accretively propelling said feedstock solids carbonaceous material for processing within said gasifier system comprises the step of feedstock potential energy accretively propelling said feedstock solids carbonaceous material for processing within said gasifier system.

695. A method for select synthesis gas generation from carbonaceous materials as described in claim 694 wherein the step of feedstock potential energy accretively propelling said feedstock solids carbonaceous material for processing within said gasifier system comprises the step of driving said feedstock solids carbonaceous material up an incline for processing within said gasifier system.

696. A method for select synthesis gas generation from carbonaceous materials as described in claim 660 wherein the step of inputting a feedstock solids carbonaceous material comprises the step of driving said feedstock solids carbonaceous material up an incline for processing within said gasifier system.

697. A method for select synthesis gas generation from carbonaceous materials as described in claim 696 and further comprising the step of pneumatically propelling said feedstock solids carbonaceous material for processing within said gasifier system.

698. A method for select synthesis gas generation from carbonaceous materials as described in claim 697 wherein the step of pneumatically propelling said feedstock solids carbonaceous material for processing within said gasifier system comprises the step of flue gas propelling said feedstock solids carbonaceous material for processing within said gasifier system.

699. A method for select synthesis gas generation from carbonaceous materials as described in claim 697 wherein the step of pneumatically propelling said feedstock solids carbonaceous material for processing within said gasifier system comprises the step of product synthesis gas propelling said solid carbonaceous material for processing within said gasifier system.

700. A method for select synthesis gas generation from carbonaceous materials as described in claim 660, 691, or 697 wherein the step of inputting a feedstock solids carbonaceous material comprises the step of pre-heating said feedstock solids carbonaceous material prior to processing within said gasifier system.

701. A method for select synthesis gas generation from carbonaceous materials as described in claim 700 wherein the step of inputting a feedstock solids carbonaceous material further comprises the step of displacing at least some oxygen from said feedstock solids carbonaceous material.

702. A method for select synthesis gas generation from carbonaceous materials as described in claim 660 wherein the step of inputting a feedstock solids carbonaceous material comprises the step of coaxially feeding to input said feedstock solids carbonaceous material.

703. A method for select synthesis gas generation from carbonaceous materials as described in claim 702 wherein the step of coaxially feeding to input said feedstock solids carbonaceous material comprises the steps of:

outer coaxially feeding a flue gas; and

inner coaxially feeding a feedstock solids carbonaceous material into said gasifier system.

704. A method for select synthesis gas generation from carbonaceous materials as described in claim 702 wherein the step of coaxially feeding to input said feedstock solids carbonaceous material comprises the step of establishing opposite coaxial flows.

705. A method for select synthesis gas generation from carbonaceous materials as described in claim 660 and further comprising the step of injecting a negatively electrostatically enhanced water species into said gasifier system to affect said at least one step of processing.

706. A method for select synthesis gas generation from carbonaceous materials as described in claim 660 and further comprising the steps of:

selectively separating processed carbonaceous material into at least a first processed materials portion and a second processed materials portion;

returning said first processed materials portion within said gasifier system; and

mixing said first processed materials portion with additionally input carbonaceous material.

707. A method for select synthesis gas generation from carbonaceous materials as described in claim 660 and further comprising the step of stoichiometrically controlling carbon content in a manner significantly appropriate for a select product gas.

708. A method for select synthesis gas generation from carbonaceous materials as described in claim 660 and further comprising the steps of:

generating at least some contaminated select product gas;

solubilizing said significant number of contaminants from said contaminated select product gas to create scrubbed select product gas;

returning at least some of said significant number of contaminants within said gasifier system at the point of at least one selected location; and

reprocessing said returned contaminants in said feedstock solids carbonaceous material gasifier system.

709. A method for select synthesis gas generation from carbonaceous materials as described in claim 660 and further comprising the step of displacing at least some oxygen from said feedstock solids carbonaceous material.

710. A method for select synthesis gas generation from carbonaceous materials as described in claim 660 and further comprising the step of returning a flue gas within said gasifier system at the point of at least one selected location.

710-801. -801. (canceled)