A method and system for continuous production of contaminant free and size specific biochar using downdraft gasification of variable quality feedstock. The system and process of the present invention includes the transfer of biochar from a gasifier after gasification to a temperature-controlled cooling screw conveyor, into a drum magnet for ferrous metal removal into multiple diverters to separate and remove ungasified materials and non-ferrous metal contaminants, then transferred into a granulator for grinding and screening the biochar to a pre-selected size. By directly attaching a novel and continuous product treatment process to the biochar stream as it exits the gasifier, the particle size, moisture content, carbon content and yield of a contaminant free biochar product can be narrowly controlled and improved to meet strict product quality specifications required by specialty applications.

A method and system for continuous production of contaminant free and size specific biochar using downdraft gasification of variable quality feedstock. The system and process of the present invention includes the transfer of biochar from a gasifier after gasification to a temperature-controlled cooling screw conveyor, into a drum magnet for ferrous metal removal into multiple diverters to separate and remove ungasified materials and non-ferrous metal contaminants, then transferred into a granulator for grinding and screening the biochar to a pre-selected size. By directly attaching a novel and continuous product treatment process to the biochar stream as it exits the gasifier, the particle size, moisture content, carbon content and yield of a contaminant free biochar product can be narrowly controlled and improved to meet strict product quality specifications required by specialty applications.

This invention relates to a method and a reactor for gasifying a carbonaceous feedstock material. The method includes the steps of choke-feeding a carbonaceous feedstock material into a pyrolysis zone of the reactor to form a discharge bed; heating the discharge bed to initiate pyrolysis of the feedstock material to form a pyrolysis product; providing a lower lying upper oxidation zone; gasifying the pyrolysis product to form a bed of char; converting thermal energy into chemical energy in an upper reduction zone; providing a lower lying lower oxidation zone; collecting any metal slag and/or slag melts in the lower oxidation zone; and discharging hot reducing gases having a temperature of at least 1300° C. and a CO/CO.sub.2 ratio of ≥5, more preferably ≥15.

This invention relates to a method and a reactor for gasifying a carbonaceous feedstock material. The method includes the steps of choke-feeding a carbonaceous feedstock material into a pyrolysis zone of the reactor to form a discharge bed; heating the discharge bed to initiate pyrolysis of the feedstock material to form a pyrolysis product; providing a lower lying upper oxidation zone; gasifying the pyrolysis product to form a bed of char; converting thermal energy into chemical energy in an upper reduction zone; providing a lower lying lower oxidation zone; collecting any metal slag and/or slag melts in the lower oxidation zone; and discharging hot reducing gases having a temperature of at least 1300° C. and a CO/CO.sub.2 ratio of ≥5, more preferably ≥15.

A method of producing oil, gas, and ash fertilizer from a feedstock includes inputting the feedstock into a reaction chamber having a wall, and combusting the feedstock in the reaction chamber. An electrical current flow is induced between the reaction chamber wall and the feedstock so as to cause arcing in the feedstock within the reaction chamber. Ash reaction byproducts migrate downward through the reaction chamber onto ash support structure, which is substantially electrically isolated from the reaction chamber wall. Gas and liquid reaction byproducts migrate upward through the reaction chamber to an upper chamber by a partial vacuum in the upper chamber, and are evacuated therefrom. The oil and gas are then separated from the evacuated gas/liquid products, providing the oil and the gas products. The oil is refinable, the gas is high in energy content, and the ash fertilizer is high in nitrogen.

A method of producing oil, gas, and ash fertilizer from a feedstock includes inputting the feedstock into a reaction chamber having a wall, and combusting the feedstock in the reaction chamber. An electrical current flow is induced between the reaction chamber wall and the feedstock so as to cause arcing in the feedstock within the reaction chamber. Ash reaction byproducts migrate downward through the reaction chamber onto ash support structure, which is substantially electrically isolated from the reaction chamber wall. Gas and liquid reaction byproducts migrate upward through the reaction chamber to an upper chamber by a partial vacuum in the upper chamber, and are evacuated therefrom. The oil and gas are then separated from the evacuated gas/liquid products, providing the oil and the gas products. The oil is refinable, the gas is high in energy content, and the ash fertilizer is high in nitrogen.

Processes for producing high biogenic concentration Fischer-Tropsch liquids derived from the organic fraction of municipal solid wastes (MSW) feedstock that contains a relatively high concentration of biogenic carbon (derived from plants) and a relatively low concentration of non-biogenic carbon (derived from fossil sources) wherein the biogenic content of the Fischer-Tropsch liquids is the same as the biogenic content of the feedstock.

Processes for producing high biogenic concentration Fischer-Tropsch liquids derived from the organic fraction of municipal solid wastes (MSW) feedstock that contains a relatively high concentration of biogenic carbon (derived from plants) and a relatively low concentration of non-biogenic carbon (derived from fossil sources) wherein the biogenic content of the Fischer-Tropsch liquids is the same as the biogenic content of the feedstock.

Herein disclosed are apparatus and associated methods related to producing an enhanced surface area biochar product with a desired activation level based on receiving biochar into a processing vessel configured with multiple independently temperature-controlled chambers and counter-flow steam injection, controlling activation levels of the biochar by moving the biochar through the processing vessel and adjusting the temperature of the biochar by injecting steam into at least one temperature-controlled chamber of the processing vessel, recovering volatiles driven off through dehydration using a thermal oxidizer, cooling the biochar to a desired discharge temperature using steam and retention time, and discharging the activated biochar product. The processing vessel may be a calciner, a rotary calciner, or a kiln. Biochar may be heated or cooled to a desired thermochemical processing temperature depending on the temperature of the received biochar. Counter-flow saturated steam may sweep volatile gases to a thermal oxidizer using a vacuum system.

The present invention discloses a gasifier and/or a gasification process that provides a long, uniform temperature zone in the gasifier, regardless of the particle size, chemical composition, and moisture content of the fuel by sandwiching a reduction zones between two oxidation zones. The gasifier and/or gasification process has a char that is more energy-dense and almost devoid of moisture that affords for an additional (or char) oxidation zone with a temperature that is higher than a first oxidation zone which is closer to an evaporation and devolatilization zone. As such, the additional (or char) oxidation zone contributes to augmenting the reduction zone temperature, thereby providing a favorable dual impact in improving syngas composition and near-complete conversion of the tar.