Clean, safe and efficient methods, systems, and processes for utilizing thermolysis methods to processes to convert various carpet, rug, polymeric materials and other waste sources, such as solid waste, tires, manure, auto shredder residue, glass and carbon fiber composite materials, municipal solid wastes, medical wastes, waste wood and the like into a Clean Fuel Gas and Char source are disclosed. The invention processes the carpet, rug, polymeric material to effectively shred and/or grind the waste source, such as post-consumer carpet remnants and waste, and then process using thermolysis methods to destroy and/or separate halogen and other dangerous components to provide a Clean Fuel Gas and Char source. Additional waste sources, such as solid waste, tires, manure, auto shredder residue, glass and carbon fiber composite materials, municipal solid wastes, medical wastes, waste wood and the like, are suitable for the processing of the invention disclosed.

Provided is a first step of causing hydrogen and carbon oxide to react with each other in a presence of a first catalyst to obtain a first fuel gas 2 that contains 2% to 10% hydrogen by volume after dehydration; and a second step of consuming the hydrogen in the first fuel gas 2 to obtain a second fuel gas 4 with a reduced hydrogen concentration. The first catalyst includes a methanation catalyst. The second step includes an exothermic reaction that generates heat of 60 kJ or more per mole of hydrogen, and the exothermic reaction is a reaction through which the hydrogen in the first fuel gas 2 and a predetermined reactant 3 are caused to react with each other in a presence of a second catalyst to generate water or a paraffin hydrocarbon with two to four carbon atoms.

The present disclosure includes a process for pelletizing a spent bleaching earth (SBE) into a clay-biocarbon composite including classifying the SBE based on at least one parameter of the SBE, selecting at least one filler compound and mixing the at least one filler compound with the SBE to make a mixture, forming a plurality of pellets out of the mixture, and pyrolyzing the pellets to produce the clay-biocarbon composite. Pyrolyzing a pelleted spent bleaching earth (SBE) may include advancing the pelleted SBE with a distributer to a first thermal chamber for providing even thermal processing, releasing the pelleted SBE to an auger to cool to room temperature, and condensing at least one volatile compound emitted from the pelleted SBE during thermal processing to produce a condensate for reuse.

The present disclosure includes a process for pelletizing a spent bleaching earth (SBE) into a clay-biocarbon composite including classifying the SBE based on at least one parameter of the SBE, selecting at least one filler compound and mixing the at least one filler compound with the SBE to make a mixture, forming a plurality of pellets out of the mixture, and pyrolyzing the pellets to produce the clay-biocarbon composite. Pyrolyzing a pelleted spent bleaching earth (SBE) may include advancing the pelleted SBE with a distributer to a first thermal chamber for providing even thermal processing, releasing the pelleted SBE to an auger to cool to room temperature, and condensing at least one volatile compound emitted from the pelleted SBE during thermal processing to produce a condensate for reuse.

Traditional residential and industrial furnace systems convert the chemical energy of liquid and gas fuels into thermal energy and, in some earlier applications, also into electric energy. This process is driven by a burner specifically designed and built. Often these systems operate at high temperatures, high pressures and relatively lower efficiency levels. The field of present invention generally relates to furnaces that combine the fuel production to the both thermal either electrical energy production. More particularly, the present invention produces a combustible gas that, within the internal workings of the present invention, and can efficiently be burned without the production of high levels of pollutants, at relatively lower temperatures and pressures. The foregoing characteristics, along with the limited size of the elements needed to practice the present invention, make it conducive for use as and in connection with, among other things, residential furnaces and other heating systems, including, for example, heat exchangers and residential hot water tanks. In short, the present invention involves the production of a combustible fuel gas, thermal and electric energy. This production is accomplished through the interconnected use of water electrolysis, catalysts, storage means, regulation, and mean of reusing materials to increase production efficiencies.

Traditional residential and industrial furnace systems convert the chemical energy of liquid and gas fuels into thermal energy and, in some earlier applications, also into electric energy. This process is driven by a burner specifically designed and built. Often these systems operate at high temperatures, high pressures and relatively lower efficiency levels. The field of present invention generally relates to furnaces that combine the fuel production to the both thermal either electrical energy production. More particularly, the present invention produces a combustible gas that, within the internal workings of the present invention, and can efficiently be burned without the production of high levels of pollutants, at relatively lower temperatures and pressures. The foregoing characteristics, along with the limited size of the elements needed to practice the present invention, make it conducive for use as and in connection with, among other things, residential furnaces and other heating systems, including, for example, heat exchangers and residential hot water tanks. In short, the present invention involves the production of a combustible fuel gas, thermal and electric energy. This production is accomplished through the interconnected use of water electrolysis, catalysts, storage means, regulation, and mean of reusing materials to increase production efficiencies.

A method and system for cost-effectively converting a feedstock using thermal plasma, or other styles of gassifiers, into an energy transfer system using a blended syngas. The feedstock is any organic material or fossil fuel to generate a syngas. The syngas is blended with any fuel of a higher thermal content (BTU) level, such as natural gas. The blended syngas high thermal content fuel can be used in any energy transfer device such as a boiler for simple cycle Rankine systems, an internal combustion engine generator, or a combined cycle turbine generator system. The quality of the high thermal content fuel is monitored using a thermal content monitoring feedback system and a quenching arrangement.

A radiant, non-catalytic recuperative reformer has a flue gas flow path for conducting hot exhaust gas from a thermal process and a reforming mixture flow path for conducting a reforming mixture. At least a portion of the reforming mixture flow path is positioned adjacent to the flue gas flow path to permit heat transfer from the hot exhaust gas to the reforming mixture. The reforming mixture flow path contains substantially no material commonly used as a catalyst for reforming hydrocarbon fuel (e.g., nickel oxide, platinum group elements or rhenium), but instead the reforming mixture is reformed into a higher calorific fuel via reactions due to the heat transfer and residence time. In a preferred embodiment, a portion of the reforming mixture flow path is positioned outside of flue gas flow path for a relatively large residence time.

A radiant, non-catalytic recuperative reformer has a flue gas flow path for conducting hot exhaust gas from a thermal process and a reforming mixture flow path for conducting a reforming mixture. At least a portion of the reforming mixture flow path is positioned adjacent to the flue gas flow path to permit heat transfer from the hot exhaust gas to the reforming mixture. The reforming mixture flow path contains substantially no material commonly used as a catalyst for reforming hydrocarbon fuel (e.g., nickel oxide, platinum group elements or rhenium), but instead the reforming mixture is reformed into a higher calorific fuel via reactions due to the heat transfer and residence time. In a preferred embodiment, a portion of the reforming mixture flow path is positioned outside of flue gas flow path for a relatively large residence time.

A remedial pollution control system for treating volatile organic compounds that may include a vapor concentrator connected to a line that is laden with volatile organic compounds, the concentrator has an organic condensate output line and a vapor output line; a mixing chamber adapted to receive air provided from an air supply line, combustible fuel from an alternate fuel supply line, and a vapor stream from the vapor output line to produce a mixed fuel supplied to an internal combustion engine, a control mixing system with a controller for producing a proper air to fuel ratio in the mixed fuel supply, and power generated to operate other devices used to more efficiently abate volatile organic compounds and reduce greenhouse gas emissions.