The invention provides a method of sequential pyrolysis and carbon deposition to produce a composite carbonaceous product, the method comprising: a pyrolysis process step comprising pyrolyzing a pyrolyzable organic feed at a pyrolysis temperature in a first reaction zone in the presence of a non-oxidising gas to produce hot char and pyrolysis gas, wherein the pyrolysis gas and the non-oxidising gas combine to form a gas mixture; discharging the gas mixture from the first reaction zone to a combustion zone and combusting at least a portion of the pyrolysis gas therein, wherein heat produced by the combusting of the pyrolysis gas is transmitted from the combustion zone to the first reaction zone to provide at least a portion of the heat of pyrolysis; and a decomposition process step comprising contacting a hydrocarbon-rich organic gas with the hot char directly after its production in the pyrolysis process step, wherein the hydrocarbon-rich organic gas catalytically decomposes on the hot char at a decomposition temperature which is higher than the pyrolysis temperature, thereby producing gaseous decomposition products comprising hydrogen and a composite carbonaceous material comprising the char with carbon deposits thereon.

Systems and processes provide for a thermal process to transform sludge (and a variety of other natural waste materials) into electricity. Dewatered sludge and other materials containing a high amount of latent energy are dried into a powdered biofuel using a drying gas produced in the system. The drying gas is recirculated and is heated by the biofuel produced in the system, waste heat (from turbines or internal combustion engines), gas (including natural gas or digester gas) and/or oil. The biofuel is combusted in a boiler system that utilizes a burner operable to burn biofuel and produce heat utilized in a series of heat exchangers that heat the recirculating drying air and steam that powers the turbines for electricity production.

A combustor for burning waste material includes a horizontally extended combustion chamber through which a mixture of waste material and air is introduced under pressure tangentially for establishing a vortical movement of the waste material toward one of the end walls. The waste material is ignited during its vortical movement. A second discharge port extends for discharging from the chamber non-combustible material entrained in the outer region of the vortex. The discharged material is conveyed through a conduit to a separator which separates the discharged gases and solid material. A secondary air manifold supplies air through controlled and automated dampers at portals positioned at intervals along the length of the chamber. An adjustable baffle is mounted on the flue adjacent its open end for deflecting outwardly toward the side wall solid material which moves from adjacent the one end wall toward the open end of the flue. A recuperator is mounted externally to the chamber on the exhaust flue, supplying heated air to the secondary air manifold and to the primary air and waste feed intake. Additionally, control means are provided for the use of specialized sensors to monitor the temperature, air flow and volume of the chamber, integrated into a process automation system that allows for control of individual components, stages, regions, as well as the entire process.

A process of making a fuel product from a non-combustible high protein organic material such as a biological by-product or waste material. The moisture content of the high protein organic material is mechanically reduced and dried to reduce the moisture content to less than ten percent (10%). The high protein organic material is pulverized to a particle size of less than about 2 mm. The high protein organic waste material is fed into a combustion chamber and separated during combustion such as by spraying of the high protein organic waste material within the combustion chamber. Temperature and nitrogenous hydrocarbon combustion reactions within the combustion chamber are also controlled by injection of steam within the combustion chamber. The concentration of protein thermal decomposition by-products, the temperature and/or pressure within the combustion chamber is also controlled to degrade hazardous polyfluoro compounds into less hazardous compounds.

A combustor for burning waste material includes a horizontally extended combustion chamber through which a mixture of waste material and air is introduced under pressure tangentially for establishing a vortical movement of the waste material, and is ignited during its vortical movement. A second discharge port extends for discharging from the chamber non-combustible waste material, to a separator which separates the discharged gases and solid material. A secondary air manifold supplies air through controlled dampers at portals positioned at intervals along the length of the chamber. An adjustable baffle is mounted internally on the flue adjacent its open end for deflecting outwardly toward the side wall any combustible material not yet destroyed. A recuperator is mounted externally to the chamber on the exhaust flue, supplying heated air used with primary air flow. Additionally, control means are provided for the use of sensors to monitor the chamber conditions.

A combustion/pyrolization system comprising a combustion/pyrolization chamber supported by the base frame, and a perforated grate forms a bottom surface of the combustion/pyrolization chamber and facilitates passage of char and boichar therethrough. The combustion/pyrolization chamber is open along at a top and an air manifold supplies a first source of combustion air across the top of the combustion/pyrolization chamber to form an air curtain. A char collection/transfer chamber is located below the perforated grate for collecting at least the char and boichar that passes therethrough, and a conveying mechanism transfers the char and boichar out of the combustion/pyrolization system for collection and use. An air plenum chamber cools the char collection/transfer chamber such that the supplied secondary air becomes heated, and the heated secondary air flows into the char collection/transfer chamber and through the perforated grate into the combustion/pyrolization chamber to provide secondary combustion air.

A combustion kiln system, comprising: a pre-heating chamber which is supplied with waste product; and a combustion chamber which receives the waste product from the pre-heating chamber and in which the waste product is incinerated; wherein the pre-heating chamber heats the waste product to remove moisture from the waste product prior to transfer to the combustion chamber.

Systems and processes provide for a thermal process to transform sludge (and a variety of other natural waste materials) into electricity. Dewatered sludge and other materials containing a high amount of latent energy are dried into a powdered biofuel using a drying gas produced in the system. The drying gas is recirculated and is heated by the biofuel produced in the system, waste heat (from turbines or internal combustion engines), gas (including natural gas or digester gas) and/or oil. The biofuel is combusted in a boiler system that utilizes a burner operable to burn biofuel and produce heat utilized in a series of heat exchangers that heat the recirculating drying air and steam that powers the turbines for electricity production.

A carbonaceous feedstock gasification power generation facility, and a method for regulating a gas for drying gas this carbonaceous feedstock, are disclosed with which it is possible to expand the range of the types of carbonaceous feedstocks that can be used. High-temperature exhaust gas, low-temperature exhaust gas and extreme high-temperature exhaust gas are bled from the furnace respectively at a high-temperature bleed position, a low-temperature bleed position and an extreme high-temperature bleed position. When these exhaust gases are mixed, the flow volume of the extreme high-temperature exhaust gas supplied to at least one of the exhaust gases, that is, the high-temperature exhaust gas or the low-temperature exhaust gas, is adjusted such that the temperature of at least one of these exhaust gases, that is, the high-temperature exhaust gas or the low-temperature exhaust gas, reaches a prescribed temperature.

An energy-saving sludge drying disposal system is provided. The disposal system includes a vacuum heating unit, an incinerating unit, a vacuum cooling unit and a molten salt heat exchanging unit. The vacuum cooling unit includes a high-temperature gas inlet, a condensed water outlet, a low-temperature gas outlet, a low-temperature liquid inlet and a medium-temperature liquid outlet. The high-temperature gas inlet of the vacuum cooling unit is connected with the vacuum heating unit. The incinerating unit includes an incinerator, an incineration gas inlet, a combustion-supporting gas inlet, a flue gas discharge outlet, a cold molten salt inlet and a hot molten salt outlet. The incineration gas inlet is connected with the low-temperature gas outlet of the vacuum cooling unit. The molten salt heat exchanging unit includes a cold molten salt outlet, a hot molten salt inlet, a medium-temperature liquid inlet and a high-temperature liquid outlet.