Methods and Apparatus for Solid Carbonaceous Materials Synthesis Gas Generation

• US 20090126276A1
• Filed: 04/11/2007
• Published: 05/21/2009
• 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 7,857,995 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

1-30. -30. (canceled)

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

inputting a feedstock solids carbonaceous material;

subjecting said feedstock solids carbonaceous material to a pressurized environment;

affirmatively establishing a stoichiometrically objectivistic chemic environment for said feedstock solids carbonaceous material in said pressurized environment;

stoichiometrically controlling carbon content in a manner significantly appropriate for a select product gas;

increasing an temperature within said pressurized environment to which said feedstock solids carbonaceous material is subjected;

pyrolytically decomposing at least a portion of said feedstock solids carbonaceous material in a solid carbonaceous materials gasifier system;

creating a pyrolytically decomposed carbonaceous material;

processing said pyrolytically decomposed carbonaceous material in said solid carbonaceous materials gasifier system;

generating at least some components of a select product gas in response to said step of processing said pyrolytically decomposed carbonaceous material;

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

32. A method for select synthesis gas generation from solid carbonaceous materials as described in claim 31 wherein said steps of affirmatively establishing a stoichiometrically objectivistic chemic environment and stoichiometrically controlling carbon content comprise the step of varying said input feedstock solids carbonaceous material.

33. A method for select synthesis gas generation from solid carbonaceous materials as described in claim 32 wherein said step of varying said input feedstock solids carbonaceous material comprises the step of varying selected from the group consisting of:

varying a carbon content, varying an oxygen content, varying a hydrogen content, varying a water content, varying a particle size property, varying a hardness property, varying a density property, varying a wood waste content, varying a municipal solid waste content, varying a garbage content, varying a sewage solids content, varying a manure content, varying a biomass content, varying a rubber content, varying a coal content, varying a petroleum coke content, varying a food waste content, and varying an agricultural waste content.

34. A method for select synthesis gas generation from solid carbonaceous materials as described in claim 31 wherein said step of outputting at least some select product gas comprises the step of varying said output select product gas.

35. A method for select synthesis gas generation from solid carbonaceous materials as described in claim 34 wherein said step of varying said output select product gas comprises the step of varying selected from the group consisting of:

varying a carbon monoxide content of a select product gas, outputting a primarily carbon monoxide select product gas, varying a hydrogen content of a select product gas, outputting a primarily hydrogen gas select product gas, varying a methane content of a select product gas, outputting a primarily methane select product gas, outputting a select product gas of primarily carbon monoxide and hydrogen gas and methane, controlling a molar ratio of a select product gas, outputting a select product gas having a controlled hydrogen gas to carbon monoxide molar ratio of from 1;

1 up to 20;

1 by volume, outputting a select product gas having a controlled hydrogen gas to carbon monoxide molar ratio of at least about 1;

1, outputting a select product gas having a controlled hydrogen gas to carbon monoxide molar ratio of at least about 2;

1, outputting a select product gas having a controlled hydrogen gas to carbon monoxide molar ratio of at least about 3;

1, outputting a select product gas having a controlled hydrogen gas to carbon monoxide molar ratio of at least about 5;

1, outputting a select product gas having a controlled hydrogen gas to carbon monoxide molar ratio of at least about 10;

1, outputting a select product gas having a controlled hydrogen gas to carbon monoxide molar ratio from at least about 1;

1 to about 20;

1, outputting a select product gas having a controlled hydrogen gas to carbon monoxide molar ratio from at least about 2;

1 to about 20;

1, outputting a select product gas having a controlled hydrogen gas to carbon monoxide molar ratio from at least about 3;

1 to about 20;

1, outputting a select product gas having a controlled hydrogen gas to carbon monoxide molar ratio from at least about 5;

1 to about 20;

1, outputting a select product gas having a controlled hydrogen gas to carbon monoxide molar ratio from at least about 10;

1 to about 20;

1, outputting producer gas, outputting synthesis gas, outputting a variable chemistry base stock, outputting a liquid fuel base stock, outputting a methanol base stock, outputting an ethanol base stock, outputting a refinery diesel base stock, outputting a biodiesel base stock, outputting a dimethyl-ether base stock, outputting a mixed alcohols base stock, outputting an electric power generation base stock., and outputting a natural gas equivalent energy value base stock.

36. A method for select synthesis gas generation from solid carbonaceous materials as described in claim 31 wherein said steps of affirmatively establishing a stoichiometrically objectivistic chemic environment and stoichiometrically controlling carbon content comprise the steps of selecting a product gas to output, evaluating a feedstock solids carbonaceous material input, and determining a chemical reaction sequence appropriate to yield said select product gas from said feedstock solids carbonaceous material.

37. A method for select synthesis gas generation from solid carbonaceous materials as described in claim 36 further comprising the step of supplying chemical reactants selected from the group consisting of:

supplying chemical reactants sufficient to satisfy the molar ratios of said chemical reaction sequence, supplying chemical reactants sufficient to substantially completely chemically react said feedstock solids carbonaceous material, supplying chemical reactants sufficient to produce a high output of said select product gas, and supplying chemical reactants sufficient to temporally accelerate said chemical reaction sequence.

38. A method for select synthesis gas generation from solid carbonaceous materials as described in claim 31 wherein said steps of affirmatively establishing a stoichiometrically objectivistic chemic environment and stoichiometrically controlling carbon content comprise the step of injecting a flue gas.

39. A method for select synthesis gas generation from solid carbonaceous materials as described in claim 38 wherein said step of injecting a flue gas comprises the step of pressurizing said flue gas.

40. A method for select synthesis gas generation from solid carbonaceous materials as described in claim 39 wherein said step of pressurizing said flue gas comprises the step of pressurizing said flue gas to at least 80 psi.

41. A method for select synthesis gas generation from solid carbonaceous materials as described in claim 38 wherein said step of injecting a flue gas comprises the step of preheating said flue gas.

42. A method for select synthesis gas generation from solid carbonaceous materials as described in claim 41 wherein said step of preheating said flue gas comprises the step of preheating to a temperature selected from the group consisting of:

preheating to at least 125 degrees Fahrenheit, preheating to at least 135 degrees Fahrenheit, preheating to at least 300 degrees Fahrenheit, preheating to at least 600 degrees Fahrenheit, and preheating to at least 1640 degrees Fahrenheit.

43. A method for select synthesis gas generation from solid carbonaceous materials as described in claim 41 wherein said step of preheating said flue gas comprises the step of preheating in a gasifier system process enclosure.

44. A method for select synthesis gas generation from solid carbonaceous materials as described in claim 38 wherein said step of injecting a flue gas comprises the step of recycling said flue gas.

45. A method for select synthesis gas generation from solid carbonaceous materials as described in claim 44 wherein said step of recycling said flue gas comprises the step of recycling selected from the group consisting of:

recycling to a pretreatment area, recycling to a pyrolysis chamber, recycling to a multiple coil carbonaceous reformation vessel, recycling to a preliminary reformation coil of a multiple coil carbonaceous reformation vessel, recycling to a secondary reformation coil of a multiple coil carbonaceous reformation vessel, and recycling to a tertiary coil of a multiple coil carbonaceous reformation vessel.

46. A method for select synthesis gas generation from solid carbonaceous materials as described in claim 38 wherein said step of injecting a flue gas comprises the step of affecting at least one process determinative parameter.

47. A method for select synthesis gas generation from solid carbonaceous materials as described in claim 46 wherein said step of affecting comprises the step of affecting selected from the group consisting of:

raising a temperature, maintaining a pressure, raising a pressure, chemically reacting, temporally accelerating a chemical reaction sequence, displacing at least some oxygen content from a feedstock solids carbonaceous material, displacing at least some water content from a feedstock solids carbonaceous material, affirmatively establishing a stoichiometrically objectivistic chemic environment for said feedstock solids carbonaceous material, and stoichiometrically controlling carbon content.

48. A method for select synthesis gas generation from solid carbonaceous materials as described in claim 31 wherein said steps of affirmatively establishing a stoichiometrically objectivistic chemic environment and stoichiometrically controlling carbon content comprise the step of purging process superfluous materials.

49. A method for select synthesis gas generation from solid carbonaceous materials as described in claim 48 wherein said step of purging process superfluous materials comprises the step of purging selected from the group consisting of:

purging oxygen and purging nitrogen.

50. A method for select synthesis gas generation from solid carbonaceous materials as described in claim 48 wherein said step of purging process superfluous materials comprises the steps of oxidizing metals and electrostatically attracting said oxidized metals.

51. A method for select synthesis gas generation from solid carbonaceous materials as described in claim 31 wherein said steps of affirmatively establishing a stoichiometrically objectivistic chemic environment and stoichiometrically controlling carbon content comprise the step of adding process beneficial materials.

52. A method for select synthesis gas generation from solid carbonaceous materials as described in claim 51 wherein said step of adding process beneficial materials comprises the step of adding selected from the group consisting of:

adding carbon, adding hydrogen, adding carbon monoxide, adding water, adding preheated water, adding a negatively electrostatically enhanced water species, adding steam, adding negatively electrostatically enhanced steam, adding recycled select product gas, adding wet recycled select product gas, and adding dry recycled select product gas.

53. A method for select synthesis gas generation from solid carbonaceous materials as described in claim 31 wherein said steps of affirmatively establishing a stoichiometrically objectivistic chemic environment and stoichiometrically controlling carbon content comprise the step of recycling.

54. A method for select synthesis gas generation from solid carbonaceous materials as described in claim 53 wherein said step of recycling comprises the step of recycling selected from the group consisting of:

recycling water, recycling preheated water, recycling a negatively electrostatically enhanced water species, recycling a preheated negatively electrostatically enhanced water species, recycling steam, recycling negatively electrostatically enhanced steam, recycling an incompletely pyrolytically decomposed carbonaceous material, recycling carbon monoxide, recycling select product gas, recycling wet select product gas, recycling dry select product gas, recycling carbonaceous particles of at least 350 micron particle size, recycling carbonaceous particles of at least 150 micron particle size, recycling carbonaceous particles of at least 130 micron particle size, recycling carbonaceous particles of at least 80 micron particle size, recycling carbonaceous particles of at least 50 micron particle size, recycling to a pretreatment area, recycling to a pyrolysis chamber, and recycling to a multiple coil carbonaceous reformation vessel.

55. A method for select synthesis gas generation from solid carbonaceous materials as described in claim 31 wherein said steps of affirmatively establishing a stoichiometrically objectivistic chemic environment and stoichiometrically controlling carbon content comprise the steps of sensing at least one process condition and responsively dynamically adjusting at least one process determinative parameter.

56. A method for select synthesis gas generation from solid carbonaceous materials as described in claim 31 wherein said steps of affirmatively establishing a stoichiometrically objectivistic chemic environment and stoichiometrically controlling carbon content comprise the steps of establishing a process set point, periodically testing at least one process condition, and responsively dynamically adjusting at least one process determinative parameter.

57. A method for select synthesis gas generation from solid carbonaceous materials as described in claim 31 wherein said steps of affirmatively establishing a stoichiometrically objectivistic chemic environment and stoichiometrically controlling carbon content comprise the steps of evaluating said feedstock solids carbonaceous material and responsively dynamically adjusting at least one process determinative parameter.

58. A method for select synthesis gas generation from solid carbonaceous materials as described in claim 31 wherein said steps of affirmatively establishing a stoichiometrically objectivistic chemic environment and stoichiometrically controlling carbon content comprise the step of removing water at a water critical pass through.

59. A method for select synthesis gas generation from solid carbonaceous materials as described in claim 31 wherein said steps of affirmatively establishing a stoichiometrically objectivistic chemic environment and stoichiometrically controlling carbon content comprise a step selected from the group consisting of:

preheating said feedstock solids carbonaceous material, controlling an oxygen content of said feedstock solids carbonaceous material, and pyrolytically decomposing said feedstock solids carbonaceous material.

60-270. -270. (canceled)

271. A solid carbonaceous materials select synthesis gas generation apparatus comprising:

a feedstock solids carbonaceous materials input;

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

at least one pressure systemjoined to at least a portion of said gasifier process flow path;

at least one stoichiometrically objectivistic carbon adjustment compensator 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 solid carbonaceous materials pyrolysis chamber through which said gasifier process flow path is routed;

a pyrolytically decomposed carbonaceous materials processor through which said gasifier process flow path is routed;

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

272-801. -801. (canceled)