An apparatus is provided for processing reusable fuel comprising: a continuous material supply assembly; a heated airlock feeder configured to continuously receive and process the material supply received therein; a reactor configured to receive the processed material from the heated airlock feeder; and a vapor refining system configured to process vapor supplied by the reactor. The apparatus may comprise a char disposal system configured to eliminate char from the reactor. The apparatus may also comprise a thermal expansion system configured to allow thermal expansion of the reactor. A cooling system may be configured to receive processed fuel from the reactor.

gasifier and a gasification process 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 gasification process produces a char that is more energy-dense and almost devoid of moisture, affording an additional (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 (char) oxidation zone contributes to augmenting the reduction zone temperature, providing a favorable dual impact in improving syngas composition and near-complete conversion of the tar.

The present invention provides a process and apparatus for converting feedstock comprising biomass and/or carbon-containing solid waste material to synthesis gas. The process comprises supplying the feedstock to a gasifier comprising a fluidized bed zone and a post-gasification zone and contacting the feedstock with a gasification agent at a plurality of different operating temperatures based on the ash softening temperature of the feedstock and finally recovering the synthesis gas. The apparatus is configured to perform the process and comprises a plurality of nozzles arranged at an acute angle relative to a horizontal plane of the gasifier.

Gasifiers, gasification systems, and methods for producing synthesis gas are disclosed. A gasifier can include a gasifier body. A feeder can be positioned to feed an organic material into the gasifier body. A pulse detonation burner can be located under or above the gasifier body and connected to the gasifier body to direct supersonic shockwaves upward into the gasifier body to heat the organic material and to form a jet spouted bed of the organic material or to operate as an entrained flow reactor. An outlet can be located at the gasifier body to allow removal of synthesis gas, residual ash, and other reaction products.

An apparatus and methods to eliminate PFAS from wastewater biosolids through fluidized bed gasification. The gasifier decomposes the PFAS in the biosolids at temperatures of 900-1800° F. Synthesis gas (syngas) exits the gasifier which is coupled to a thermal oxidizer and is combusted at temperatures of 1600-2600° F. This decomposes PFAS in the syngas and creates flue gas. Heat can be recovered from the flue gas by cooling the flue gas to temperatures of 400-1200° F. in a heat exchanger that is coupled with the thermal oxidizer. Cooled flue gas is mixed with hydrated lime, enhancing PFAS decomposition, with the spent lime filtered from the cooled flue gas using a filter system that may incorporate catalyst impregnated filter elements. The apparatus and methods thereby eliminate PFAS from wastewater biosolids and control emissions in the resulting flue gas.

Gasifiers, gasification systems, and methods for producing synthesis gas are disclosed. A gasifier can include a gasifier body. A feeder can be positioned to feed an organic material into the gasifier body. A pulse detonation burner can be located under or above the gasifier body and connected to the gasifier body to direct supersonic shockwaves upward into the gasifier body to heat the organic material and to form a jet spouted bed of the organic material or to operate as an entrained flow reactor. An outlet can be located at the gasifier body to allow removal of synthesis gas, residual ash, and other reaction products.

A fly ash recycling gasification furnace includes a fly ash burner, an ash remover, a fly ash storage tank, a variable pressure lock hopper, a fly ash blending system, an exhaust filter, and a backflushing nitrogen buffer tank. The fly ash burner is located on an inner wall of a hearth of the gasification furnace. The ash remover has an inlet connected to an outlet of a waste boiler of the gasification furnace. The fly ash storage tank is connected to a pressurized nitrogen inlet pipe, and a bottom outlet of the ash remover. The variable pressure lock hopper is connected to the fly ash storage tank. The fly ash blending system is connected to the variable pressure lock hopper and the fly ash burner. The exhaust filter is connected to the storage tank, the lock hopper and the blending system. The buffer tank is connected to the exhaust filter.

A feedstock flexible process for converting feedstock into oil and gas includes (i) indirectly heated hydrous devolatilization of volatile feedstock components, (ii) indirectly heated thermochemical conversion of fixed carbon feedstock components, (iii) heat integration and recovery, (iv) vapor and gas pressurization, and (v) vapor and gas clean-up and product recovery. A system and method for feedstock conversion includes a thermochemical reactor integrated with one or more hydrous devolatilization and solids circulation subsystems configured to accept a feedstock mixture, comprised of volatile feedstock components and fixed carbon feedstock components, and continuously produce a volatile reaction product stream therefrom, while simultaneously and continuously capturing, transferring, and converting the fixed carbon feedstock components to syngas.

A two-stage syngas production method to produce a final product gas from a carbonaceous material includes producing a first product gas in a first reactor, separating char from the first product gas to produce separated char and char-depleted product gas, and separately reacting the separated char and the char-depleted product gas with an oxygen-containing gas in a second reactor to produce a final product gas. The separated char is introduced into the second reactor above the char-depleted product gas. The solids separation device may include serially connected cyclones, and the separated char may be entrained in a motive fluid in an eductor to produce a char and motive fluid mixture prior to being transferred to the second reactor. A biorefinery method produces a purified product from the final product gas.

Embodiments of the invention improve the performance, safety, and efficiency of the gasification process. Embodiments of the invention improve downdraft gasification by improving upon the systems and methods for fuel preparation and by addressing gasifier bridging and channeling. Unique parts of the system include a unique hearth and grate design, a programmable logic controller and interface for managing the gasification process, an improved filtration system, a unique system for eliminating mist, a unique system for cooling gas, a unique combined flare, an integrated auger system, and a new system and method for sampling gas.