Modular syngas system, marine vessel powered thereby, and method of operation
11359150 · 2022-06-14
Assignee
Inventors
Cpc classification
C10J2300/1693
CHEMISTRY; METALLURGY
F05D2220/32
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
C01B3/02
CHEMISTRY; METALLURGY
Y02E20/18
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F02C3/22
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
C10J2300/0946
CHEMISTRY; METALLURGY
C10J2200/31
CHEMISTRY; METALLURGY
F02C6/203
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
C10J3/00
CHEMISTRY; METALLURGY
F05D2220/722
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02P30/00
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y02P20/129
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
F02C3/22
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A land based or marine vessel based system for generating power from syngas utilizes a feedstock of waste material acquired from waste dumps, municipalities, and/or ports of call of the marine vessel. The marine vessel or land based system can be retrofitted to be fueled by the waste material. The syngas is used to provide propulsive and/or electrical power for the marine vessel or the land based system. The waste material is not just a feedstock for the syngas but is provided with payment from the ports of call to take the waste material away. The marine vessel also collects garbage floating on the waterway along the voyage between the various ports of call for use as feedstock in the production of syngas. The modular syngas generation system further generates H.sub.2 from the syngas. The H.sub.2 generated thereby is used to fuel an H.sub.2 fuel cell for the generation of electrical power.
Claims
1. A marine vessel, comprising: an onboard system for producing syngas, wherein the onboard system comprises: one or more heating units; a gasification unit supplied with waste material and heated by the one or more heating units, wherein the gasification unit produces syngas from the waste material; and a scrubber having an inlet and an outlet, wherein the inlet of the scrubber is in fluid communication with the gasification unit and the syngas is passed through the scrubber; one or more hydrogen storage tanks; and one or more hydrogen fuel cells; wherein the one or more hydrogen storage tanks is connected via conduits to the outlet of the scrubber and to the one or more hydrogen fuel cells; and the one or more hydrogen fuel cells is connected via conduits to the outlet of the scrubber and to the one or more hydrogen storage tanks; and an intake assembly disposed at least on a front of the marine vessel, wherein the intake assembly is configured to collect at least a first portion of the waste material supplied to the gasification unit in the form of debris floating at or near the surface of the water through which the marine vessel passes.
2. The marine vessel of claim 1, wherein: a second portion of the waste material is supplied from a port of call of the marine vessel; and wherein the second portion of the waste material is selected from a group consisting of household waste, industrial waste, organic waste, electronics, plastic waste exclusive of polyvinyl chloride, chlorinated polyvinyl chloride, or perfluoroalkoxy alkane, agricultural waste, chemical waste, sludge, old vehicle tires, and combinations thereof.
3. A method of operation of the marine vessel of claim 2, comprising the steps of: being paid to accept the second portion of the waste material from the port of call; loading the second portion of the waste material from the port of call onto the marine vessel; utilizing the first and second portions of the waste material as a feedstock for the onboard system for producing syngas; and generating electrical power using the one or more hydrogen fuel cells.
4. The marine vessel of claim 2, further comprising: an anaerobic digester supplied with organic waste and heated by the one or more heating units, wherein the anaerobic digester produces biogas from the organic waste; wherein at least a portion of the biogas is supplied to the one or more heating units.
5. The marine vessel of claim 2, further comprising: a heat recovery chiller disposed in thermal contact between the one or more hydrogen storage tanks and the gasification unit; wherein the heat recovery chiller cools the one or more hydrogen storage tanks.
6. The marine vessel of claim 2, further comprising: one or more carbon dioxide storage tanks; wherein carbon dioxide gas is separated out from the syngas by the scrubber, and wherein the carbon dioxide gas is stored in the one or more carbon dioxide storage tanks.
7. The marine vessel of claim 2, further comprising: a closed-cycle regenerative heat engine disposed between the gasification unit and the scrubber; wherein the closed-cycle regenerative heat engine recovers heat from the syngas thereby producing useful work therefrom and providing excess waste heat back to the gasification unit.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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(10) Other aspects and advantages of the present invention will become apparent upon consideration of the following detailed description, wherein similar structures have similar reference numerals.
DETAILED DESCRIPTION
(11) The following detailed embodiments presented herein are for illustrative purposes. That is, these detailed embodiments are intended to be exemplary of the present invention for the purposes of providing and aiding a person skilled in the pertinent art to readily understand how to make and use of the present invention.
(12) Referring to
(13) In one embodiment the hot exhaust gases are directed to expand through one or more turbines. In some embodiments the one or more turbines are mechanically connected with one or more electrical generators as is known in the art, for example, as a turbine/generator assembly, illustrated schematically as element 40 in
(14) In another embodiment the hot exhaust gases are directed to a boiler for the purpose of producing steam that is then directed to expand through the turbine/generator assembly 40. For purposes of illustration, element 30 schematically represents the combustor, or a combined combustor and boiler assembly. In some embodiments the combined combustor and boiler assembly is modular comprising a modular combustor and a modular boiler that can each be swapped in or out for maintenance or repair or to accommodate changes in required capacity. Expanded exhaust gases or steam having passed through the turbine/generator assembly 40 is directed to a smokestack 50 and directed out of the vessel 10.
(15) Power generated by the turbine/generator assembly 40 can be used throughout the vessel 10 or stored in storage batteries on board the vessel 10 for later, backup, and/or emergency use throughout the vessel 10. In one embodiment for example without limitation the power generated or stored in storage batteries from prior generation is used to drive motors 60 that drive the vessel's propulsion system 70 as is known in the art. The power generated or stored in storage batteries from prior generation can also be used for driving the energy requirements of the syngas producing system 20 as well as any other systems aboard the vessel 10 requiring electrical power.
(16) In one embodiment, syngas produced by the system 20 is not directed to the combustor and boiler assembly 30, but rather is directed to a syngas storage tank 80. Syngas stored in the syngas storage tank 80 can later be directed to the combustor and boiler assembly 30, or alternatively could be directed off the vessel 10, for example, to be sold at a port of call for the vessel 10. Syngas thus sold at the port of call can subsequently be stored and/or used at the port of call for the generation of power for the port of call.
(17) In one embodiment, the syngas producing system 20 is built into the vessel 10 during manufacture thereof. In another embodiment, the syngas producing system 20 is added as a retrofit to a vessel 10 already having a system for the generation of electrical and motive power for the vessel 10. In an embodiment where the system 20 is a retrofit, any furnaces and/or pre-existing portions of the system for the generation of electrical and/or motive power of the vessel 10, including without limitation, furnaces, engines, boilers, and the like, would be removed and replaced by the elements described hereinabove for the generation of electrical and motive power using syngas made onboard in a syngas producing system 20 from a feedstock.
(18) In one embodiment the vessel 10 receives carbonaceous feedstock from one or more ports of call. The feedstock may be immediately directed to the syngas producing system 20, or alternatively, the feedstock may be stored in a feedstock storage tank 90 for later direction to the syngas producing system 20.
(19) In another embodiment, the vessel 10 collects feedstock in the form of debris floating at or near the surface of the water by moving through the water. For example, in this embodiment, the vessel 10 includes an intake assembly 100 disposed at least on a front of the vessel 10. In some embodiments the intake assembly could also be disposed along lateral sides of the vessel 10. The intake assembly 100 comprises one or more intake guides 110 that use the force of the vessel 10 moving through patches 120 of floating debris to guide a portion or all of the patches 120 of floating debris into one or more guide tubes 130 disposed through the front and/or sides of the vessel 10. As illustrated in
(20) Referring again to
(21) Referring to
(22) The barge embodiment 200 may include an independent propulsion system 70 (as shown in
(23) Utilizing the hereinabove described syngas powered vessel or barge, a cargo vessel operator can power their vessels using syngas acquired from ports of call. The municipality or other entity associated with the port of call can provide feedstock for the production of the syngas. The feedstock can be in the form of industrial or residential waste and/or other garbage that the port of call pays the cargo vessel operator to take off their hands. As an example, near major ports in the United States the cost of landfill or compost for disposal of organic waste ranges from about 110 to 200 dollars a ton. A cargo operator having the hereinabove syngas powered vessel or barge can successfully acquire all the feedstock it needs from the port of call by simply charging the port of call slightly less than the going rate, for example, by charging 10 dollars less per ton. Such a deal would not only provide feedstock for the cargo vessel operator but would also provide additional savings on fuel cost (or even profit), while having the added benefit of preventing more waste from ending up in a landfill or being incinerated.
(24) Once underway between ports, the cargo vessel operator can further utilize the above-described system to collect feedstock from the seaways, rivers, canals, and any other pathways traversed by the cargo vessel 10 or barge 200. Once again, such collection of feedstock provides a free source of fuel to the cargo vessel operator, while again having the added benefit of cleaning up waste floating in the world's waterways.
(25) Referring to
(26) Similar to the prior disclosed embodiments, syngas generated by the system 20 is fed to a combustor 30 as is known in the art. The combustor 30 burns the syngas in an appropriate mixture of gases as is known in the art to produce hot exhaust gases. In one embodiment the hot exhaust gases are directed to expand through one or more turbines. In some embodiments the one or more turbines are mechanically connected with one or more electrical generators as is known in the art, for example, as a turbine/generator assembly, illustrated schematically as element 40 in
(27) In another embodiment the hot exhaust gases are directed to a boiler for the purpose of producing steam that is then directed to expand through the turbine/generator assembly 40. For purposes of illustration, element 30 schematically represents the combustor, or a combined combustor and boiler assembly. Expanded exhaust gases or steam having passed through the turbine/generator assembly 40 is directed to a smokestack 50 and directed out of the fixed or mobile land based syngas power generation system 250.
(28) Still referring to
(29) In one embodiment of the fixed or mobile land based syngas power generation system 250, syngas produced by the system 20 is not directed to the combustor and boiler assembly 30, but rather is directed to a syngas storage tank 80. Syngas stored in the syngas storage tank 80 can later be directed to the combustor and boiler assembly 30, or alternatively could be directed out of the fixed or mobile land based syngas power generation system 250, for example, to be sold at a municipality, a power plant, or even at a port of call for a vessel 10 having a similar syngas power system as noted hereinabove. Syngas thus sold to the power plant or municipality or to the port of call can subsequently be stored and/or used for the generation of power locally or for use the grid in general.
(30) All of the embodiments described hereinabove with regard to
(31) Referring to
(32) Heat, Q, from one or more heating units 330 is applied to the anaerobic digester 310 and the contents are mixed. Upon such treatment the contents break down into a liquid waste compost and a gas also known as biogas. The liquid waste compost is diverted out of a bottom of the anaerobic digester 310 into a liquid compost tank 340. The biogas is diverted to a pipe 350 from where it can be collected in a tank 360 or further diverted to flow to the one or more heating units 330, wherein it is burned to provide at least a portion of the heat, Q, that is applied to the anaerobic digester 310.
(33) In one embodiment one or all of the anaerobic digester 310, the conveyor belt 320, the one or more heating units 330, the liquid compost tank 340, the pipe 350, and the tank 360 comprise an anaerobic digestion module 370 as indicated by the dashed lines labeled 370. In another embodiment the anaerobic digestion module 370 includes one or more of the other components illustrated in
(34) Still referring to
(35) The gasification unit 380 for example without limitation comprises a system that uses heated air and/or steam as is known in the art to produce syngas and other by products from the waste materials, for example, from the waste plastics. The waste materials fed to the gasification unit 380 may be sourced from a port of call or directly from a waste dump or from any available source of municipal waste, including being collected from the oceans and waterways as described hereinabove and/or disclosed in the '071 Provisional Patent Application. In one embodiment, the waste materials could be supplied to the gasification unit 380 for example without limitation by being carried on a conveyor belt 390.
(36) In addition to producing syngas, the gasification unit 380 produces other by products of various molecular weights. Tars and slag are collected into one or more slag tanks 400. Hydrocarbon oils are separated from the tars and slag and collected into one or more oil totes/tanks 110 for resale as fuels.
(37) In one embodiment one or all of the gasification unit 380, the conveyor belt 390, the one or more slag tanks 400, and the one or more oil totes/tanks 410 comprise a gasification module 415 as indicated by the dashed lines labeled 415. In another embodiment the gasification module 415 includes one or more of the other components illustrated in
(38) The produced syngas, which is a mixture of gases comprising hydrogen (H.sub.2) is passed from the gasification unit 380 to a scrubber 420 as is known in the art, which cools the syngas and removes any unwanted impurities. In one embodiment without limitation the scrubber 420 is a wet scrubber as is known in the art, wherein the syngas is brought into contact with a cleansing liquid, typically water. Cooling the syngas allows the hydrogen to be easily separated out from the other constituents.
(39) In some embodiments, the hydrogen is stored in one or more hydrogen tanks 430. In other embodiments the hydrogen could be passed directly to one or more hydrogen fuel cells 450, thereby bypassing the hydrogen storage tanks 430, or, alternatively could be passed directly to the one or more hydrogen fuel cells 450 up to the capacity of the one or more fuel cells to accept the hydrogen with any additional or over supply then being diverted into the one or more hydrogen fuel tanks 430.
(40) In embodiments having a wet scrubber 420, water used in scrubbing the syngas is passed to a recirculation tank 440 and therein passed through one or more filtering membranes that capture contaminants in the water. After passing through the one or more membranes in the recirculation tank 440 the water is returned to the scrubber 420. The water may be moved between the scrubber 420 and the recirculation tank 440 and passed through the one or more membranes by any one or more of a gravity feed, one or more pumps, or other mechanisms for moving water as is known in the art.
(41) Still referring to
(42) In one embodiment the modular syngas system 305 further includes a heat recovery chiller 470, for example, a heat exchanger or other device as is known in the art. The heat recovery chiller 470 is disposed between the one or more hydrogen tanks 430 and the gasification unit 380. In one embodiment the heat recovery chiller 470 helps to cool the one or more hydrogen tanks 430 and can further be used for other purposes as are known in the art. For example, heat recovered by the heat recovery chiller 470 could be used to heat the gasification unit 380.
(43) Similar to the anaerobic digestion module 370 and the gasification module 415, any one or more of the above described components consisting of the scrubber 420, the one or more hydrogen tanks 430, the recirculation tank 440, the one or more hydrogen fuel cells 450, the electrical engine 460, the heat recovery chiller 470, and any one or more of the other components illustrated in
(44) Referring now to
(45) Still referring to
(46) Further, any one or more of the components of the modular syngas system 505 described hereinabove consisting of the scrubber 420, the one or more hydrogen tanks 430, the recirculation tank 440, the one or more hydrogen fuel cells 450, the electrical engine 460, the heat recovery chiller 470, and any one or more of the other components illustrated in
(47) Referring now to
(48) Still referring to
(49) Still referring to
(50) Further, any one or more of the components of the modular syngas system 605 described hereinabove consisting of the scrubber 420, the one or more hydrogen tanks 430, the recirculation tank 440, the one or more hydrogen fuel cells 450, the electrical engine 460, the heat recovery chiller 470, the one or more tanks/cylinders 615, and any one or more of the other components illustrated in
(51) Referring now to
(52) Still referring to
(53) Further, any one or more of the components of the modular syngas system 705 described hereinabove consisting of the scrubber 420, the one or more hydrogen tanks 430, the recirculation tank 440, the one or more hydrogen fuel cells 450, the electrical engine 460, the heat recovery chiller 470, the one or more tanks/cylinders 615, and any one or more of the other components illustrated in
(54) Referring to
(55) By such placement of the closed-cycle regenerative heat engine 800 and/or one or more heat exchangers 801, at least a portion of the heat lost by passing the syngas from the gasifier unit 380 directly into the scrubber 420 and cooling it therein can be recovered by passing the syngas first through the one or more heat exchangers 801 and/or the one or more heat exchangers 801 connected with the closed-cycle regenerative heat engine 800. Such an arrangement allows for not only an enhanced capture of energy from the syngas, but also powers the closed-cycle regenerative heat engine 800 thereby providing increased useful work (or energy output as shown as numeral 810 in
(56) A marine vessel equipped with an embodiment of the modular syngas system 305, 505, 605, 705 can collect waste from ports, its own waste streams, and from the oceans and waterways to use as a fuel source, which could result in a non-polluting cargo ship that is self-sustaining with respect to fuel and more profitable to operate. In addition, a marine vessel or a fixed or mobile land based syngas power generation system equipped with an embodiment of the modular syngas system 305, 505, 605, 705 can also be used to provide power to other aspects of the marine vessel or to the fixed or mobile land based installation, or transmitted away from the marine vessel or fixed or mobile land based installation to feed a power grid as a source of power for cities, portions of cities, and in general.
INDUSTRIAL APPLICABILITY
(57) The modular syngas producing system, a vessel powered thereby, and the other elements and methods described herein would be highly beneficial to a vessel operator in providing cost savings and an alternative source of fuel, as well as also providing benefits to the environment. The modular syngas producing system can further generate H.sub.2 from the syngas. The H.sub.2 generated thereby is used to fuel an H.sub.2 fuel cell for the generation of electrical power. The modular syngas producing system, the combustor/combustor and boiler assembly, the turbine/generator assembly, and all the other components described hereinabove can be made in industry for the benefit of industry and for the environment.
(58) Numerous modifications to the present invention will be apparent to those skilled in the art in view of the foregoing description. It is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. Accordingly, this description is to be construed as illustrative only of the principles of the invention and is presented for the purpose of enabling those skilled in the art to make and use the invention and to teach the best mode of carrying out same. The exclusive rights to all modifications which come within the scope of the appended claims are reserved. All patents, patent publications and applications, and other references cited herein are incorporated by reference herein in their entirety.