METHOD AND APPARATUS FOR PROCESSING OF MATERIALS USING HIGH-TEMPERATURE TORCH

Abstract

A method and apparatus for reforming carbonaceous material into syngas containing hydrogen and CO gases is disclosed. In one embodiment, a hydrogen rich torch reactor is provided for defining a reaction zone proximate to torch flame. One input of the reactor receives input material to be processed. Further inputs may be provided, such as for example to introduce steam and/or gases such as methane, oxygen, hydrogen, or the like.

Claims

1. An apparatus for processing input material, comprising: a reactor vessel defining a combustion zone; the reactor vessel having at least one input for a combustible torch fuel to at least one torch nozzle, the at least one torch nozzle being adapted to generate at least one flame within said reactor; the reactor vessel further having at least one input port for receiving the input feedstock, the input feedstock being directed proximally to the at least one flame; the reactor vessel further having an output for discharging a primary reactor output stream; at least one cooler coupled to receive the primary reactor output stream and operable to cool the primary reactor output stream and generate a secondary output stream; a scrubber, coupled to receive the secondary output stream from the cooler/separator, the scrubber being operable to further extract at least one gas from the secondary output stream.

2. An apparatus in accordance with claim 1, wherein the reactor vessel further has an input for receiving a supply of steam.

3. An apparatus in accordance with claim 1, wherein the combustible torch fuel comprises hydrogen.

4. An apparatus in accordance with claim 2, wherein the combustible torch fuel further comprises methane.

5. An apparatus in accordance with claim 1, wherein the combustible torch fuel is combined with oxygen.

6. An apparatus in accordance with claim 1, wherein the combustible torch fuel comprises acetylene.

7. An apparatus in accordance with claim 1, wherein the reactor vessel further having at least one input port for receiving the input feedstock, the input feedstock being selectively directed proximally to the tip of at least one flame and intersecting that flame at angle of 90 degrees plus or minus 60 degrees.

8. An apparatus in accordance with claim 1, wherein the at least one cooler further is further operable to precipitate solid impurities from the primary reactor output stream.

9. An apparatus in accordance with claim 1, wherein the combustible torch fuel comprises less than ten percent (10%) nitrogen.

10. An apparatus in accordance with claim 1, further comprising a preheater for preheating the input feedstock prior to introduction into the reactor vessel.

11. A method for processing input material, comprising: directing an input feedstock into a reactor vessel having at least one input for a combustible torch fuel to at least one torch nozzle, the at least one torch nozzle being adapted to generate at least one flame within said reactor to define a combustion zone; directing a primary output stream from said reactor vessel into at least one cooler operable to cool the primary reactor output stream and generate a secondary output stream; directing the secondary output stream from the at least one cooler into a scrubber, the scrubber being operable to extract at least one gas from the secondary output stream.

12. A method in accordance with claim 11, further comprising introducting steam into the reactor vessel.

13. An method in accordance with claim 11, wherein the combustible torch fuel comprises hydrogen.

14. A method in accordance with claim 13, wherein the combustible torch fuel further comprises methane.

15. A method in accordance with claim 13, wherein the combustible torch fuel is combined with oxygen.

16. A method in accordance with claim 13, further comprising selectively directing the input feedstock proximally to the tip of at least one flame and intersecting that flame at angle of 90 degrees plus or minus 60 degrees.

17. A method in accordance with claim 13, wherein the scrubber is further operable to precipitate solid impurities from the primary reactor output stream.

18. A method in accordance with claim 11, wherein the combustible torch fuel comprises less than ten percent (10%) nitrogen.

19. A method in accordance with claim 11, further comprising preheating the input feedstock prior to directing the input feedstock into the reactor vessel.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The foregoing and other features and advantages described herein will be more fully appreciated by reference to a detailed description of one or more examples, when read in conjunction with the accompanying drawings, in which:

[0028] FIG. 1 is a functional block diagram of an example material processing system in accordance with this disclosure;

[0029] FIG. 2 is a block diagram of another example material processing system in accordance with this disclosure;

[0030] FIG. 3 is a perspective view of a portion of the example material processing system from FIG. 2 including a reactor portion thereof;

[0031] FIG. 4 is a top view of the portion of the example material processing system from FIG. 3;

[0032] FIG. 5 is a side view of the portion of the example material processing system from FIG. 3;

[0033] FIG. 6 is a side, cross-sectional view of the portion of the example material processing system from FIG. 3;

[0034] FIG. 7 is a side view of a torch from the example material processing system from FIG. 2;

[0035] FIG. 8 is a side, cross-sectional view of the torch from FIG. 7;

[0036] FIG. 9 is a perspective view of an implementation of the example material processing system from FIG. 2; and

[0037] FIG. 10 is a perspective, cut-away view of the implementation of the example material processing system from FIG. 2.

DETAILED DESCRIPTION

[0038] In the disclosure that follows, in the interest of clarity, not all features of actual implementations are described. It will of course be appreciated that in the development of any such actual implementation, as in any such project, numerous engineering and technical decisions must be made to achieve the developers' specific goals and subgoals (e.g., compliance with system and technical constraints), which will vary from one implementation to another. Moreover, attention will necessarily be paid to proper engineering practices for the environment in question. It will be appreciated that such development efforts might be complex and time-consuming, outside the knowledge base of typical laymen, but would nevertheless be a routine undertaking for those of ordinary skill in the relevant fields.

[0039] Referring to FIG. 1, there is shown a functional block diagram of a hydrogen/methane torch reforming system 100 in accordance with one example. As shown in FIG. 1, system 100 includes a hydrogen/methane torch reactor 102 having a number of input ports as will be hereinafter described. System 100 further comprises at least one hydrogen/methane torch 104 inserted into a port 106 of reactor 102 and adapted to produce a methane-hydrogen flame within a contained reaction zone defined within reactor 102, as will hereinafter be described in further detail. A feed input nozzle 108 is provided for introducing material to be processed and/or reformed into reactor 102. In one example, an output 110 of the reactor 102 passes through a heat exchanger 112 in order that thermal energy of the reactor output can be at least partially utilized within heat exchanged 112 to pre-heat other process elements, as herein described. Such utilization of thermal energy of output 110 from reactor 102 may advantageously contribute to an overall level of efficiency in the operation of system 100, as would be appreciated by those of ordinary skill in the art.

[0040] In one example, operation of system 100 may be continuous, such that the output 110 from reactor 102 substantially comprises a continuous stream, which may have both gaseous and particulate components. After passing through heat exchanger 112, the reactor output 110 may be applied to a cooler 114 to decrease temperature to a level associated with water vapor condensation into liquid water, which may then be produced at an output 116. In the present example, the cooled output 110 may then provided from an output 118 of cooler 114 to a separator 120. In one example, separator 120 functions to separate and extract hydrogen from the output 110 of reactor 102. Those of ordinary skill in the art will recognize that various separation techniques and technologies are known for separating and extracting hydrogen gas in a suitable manner. In one example, separator 120 may comprise a pressure swing adsorption (PSA) unit. PSA units are employed as a means of separating some gas species from a mixture of gases under pressure according to the species' molecular characteristics and affinity for an adsorbent material. Suitable PSA technologies and processes are well known to those of ordinary skill in the art.

[0041] In another example, separator 120 may comprise a centrifugal separation device such as a vortex cooler. Various suitable types and configurations of vortex coolers are known and commercially available from various suppliers.

[0042] It is contemplated that other separation technologies, including, without limitation, membrane gas separation, may be employed in conjunction with the various examples described herein.

[0043] With continued reference to FIG. 1, separator 120 functions to separate hydrogen from other components of output 110. The remaining components of output 110 may be presented at an output 122 of separator 120, while the hydrogen gas (H.sub.2) separated from the output 110 by separator 120 may be directed through at an output 124 of separator 120 to be fed back to reactor 102 to supply fuel for the flame produced by the one or more torches 104. A valve 126 may be provided to selectively control an amount of H.sub.2 fed back from separator 120 to torch 104. In addition, or in the alternative, H.sub.2 extracted by separator 120 may be provided at a separate output 128 of system 100, as selectively controlled by a valve 130.

[0044] Reactor 102 may have a number of additional input ports for receiving constituent materials for the process operation of system 100. In one example, there may be provided a source 132 of oxygen (O.sub.2) via an input 134 to reactor 102. This oxygen supply 132 may be selectively introduced by means of a valve 136. The oxygen supplied at input 134 may be combined with hydrogen (H.sub.2) and/or methane (CH.sub.4) supplied to torch 102 to create an oxy-hydrogen/methane flame.

[0045] As shown in FIG. 1, the H.sub.2 supplied to torch 104 is fed through an input 136 of torch 104 may be provided from an external H.sub.2 source 138, or may be provided from separator 120 via a feedback line 140 from separator 120, through valve 126, as herein described. As would be appreciated by those of ordinary skill, even if it is desired for most or all of the H.sub.2 needed for the oxy-hydrogen flame to be provided in a recycle arrangement from separator 120, an external H.sub.2 source 138 may be provided for the purposes of providing H.sub.2 long enough for the process to proceed for a period sufficient for a steady stream of H.sub.2 to be produced by separator 120.

[0046] Reactor 102 may also have a steam input port 142 for introducing super-heated steam into reactor 102. In one example, steam is produced by a boiler and super-heater 144 receiving an input 146 of water (H.sub.2O). An output 148 of boiler and super-heater 144 may be directed through heat exchanger 112 prior to introduction into reactor 102 through input port 142. In addition, as shown in FIG. 1, steam at output 148 of boiler and super-heater 144 may be partially directed through a valve 150 to be combined with input feedstock carried through an input line 152 to input port 108 of reactor 102. As shown in FIG. 1, in one example, input feedstock 154 may be introduced into system 100 via heat exchanger 112, thereby pre-heating the input feedstock 154 prior to introduction into reactor 102 via input port 108. Steam through valve 150 may serve as a carrier for the input feedstock 154.

[0047] Turning to FIG. 2, there is shown a block diagram of another example of a reactor system 200 for processing input material using a plurality of high-temperature torches in a reactor. In particular, system 200 in one example includes a reactor 202 having an input 204 for receiving input feedstock 206. Reactor 202 is equipped with at least one, and in the example of FIG. 2, a plurality of torches 208 for creating one or more torch flames 210 within reactor 202. In one example, reactor 202 is substantially cylindrical, and torches 208 are disposed in a spaced-apart circumferential relationship around reactor 202, such that input feedstock 206 passes transversely through torch flames 210 within reactor 202. The one or more torch flames 210 within reactor 202 define a combustion zone represented generally by dashed line 211 in FIG. 2

[0048] In one example, each torch 208 has at least one input 212 for receiving a supply of a torch fuel, such as hydrogen (H.sub.2) or methane (CH.sub.4), or a combination thereof, and an input 214 for receiving an additional input, such as oxygen (O.sub.2). As will be appreciated by those of ordinary skill having the benefit of the present disclosure, the relative amounts of torch fuel(s) and other inputs may be varied depending upon such factors as the desired temperature to be achieved at torch flames 210 and the composition of input feedstock 206. Moreover, the geometry of torch flames 210 and their positioning and orientation with respect to the path of input feedstock 206 can also influence the overall performance of system 200.

[0049] As noted above, in another example, each torch may have inputs (not shown explicitly in FIG. 2) for receiving other torch fuels or inputs. In various examples, the inputs supplied to torches 208 may comprise, separately, or in various combinations, methane, hydrogen, acetylene, oxygen, and/or nitrogen. In some examples, nitrogen may comprise less than ten percent (10%) of the torch input. It is contemplated that the composition of torch inputs introduced through inputs 212 and/or 214 of torches 208 may vary depending upon the nature and composition of input feedstock 206.

[0050] As shown in FIG. 2, torches 208 may be arranged such that input feedstock 206 passes through a plurality of stages of torch flames 210 as it passes through reactor 202, providing a sequence of relatively small volume targets for torch flames 210. In one example, and as shown in FIG. 2, torches 208, and hence torch flames 210, are oriented at an angle with respect to the sidewall of reactor 202.

[0051] With continued reference to the example of FIG. 2, reactor 202 may be provided with one or more inputs 216 for the introduction of steam into reactor 202. In one example, steam from inputs 216 is introduced downstream of torches 208, and is provided to facilitate the high-temperature reaction induced by heat from torch flames 210. In addition, in one example, additional reactants, such as methane, may be introduced into reactor 202 via one or more inputs 217, as shown in FIG. 2. Inputs 217 be positioned ahead of, within, or beyond combustion zone 211

[0052] In some examples, input feedstock 206 may be introduced into reactor 202 along with a gaseous and/or liquid carrier. In one example, an input such as fly ash, a particulate, may be carried into reactor 202 with a gaseous stream, such as a stream of methane (CH.sub.4). In another example, an input such as fly ash may be mixed with water and introduced into input 204. Once input feedstock 206 has passed through torch flames 210, with or without an accompanying carrier, a resulting primary reactor output stream 218 of processed material exits reactor 202, as shown in FIG. 2. Depending upon the composition of input feedstock 206, as described in further detail below, processed material stream 218 may include both gaseous and particulate (i.e., substantially solid) components. In one example, therefore, reactor 202 is oriented substantially vertically, as shown in FIG. 2, such that with gravity assistance, particulate components 220 of processed stream 216 may be collected in a containment portion 222 of processing system 200, while gaseous components 224 of primary reactor output stream 218 may exit as shown in FIG. 2 to a cooler/separator 226.

[0053] In some examples, input feedstock 206 may be preheated (for example, as described in the example of FIG. 1) to promote the reaction processes within reactor 202.

[0054] As in the example described above with reference to FIG. 1, cooler/separator 226 in the example of FIG. 2 may facilitate the condensation of liquid vapors, such as water vapor, contained within the gaseous component of primary reactor output stream 218. Liquids accumulated in cooler/separator 226 may be extracted from system 200 via an output line 230. As shown in FIG. 2, some amount of particulate (i.e., solid) material 232 may also accumulate in a collection area 234 of cooler/separator 226.

[0055] Although only a single cooler block 226 is depicted in FIG. 2, in some examples, more than one cooling stage may be implemented. A first stage cooler may primarily bring reactor output 224 to a temperature sufficient to precipitate out residual heavy metals and the like. Subsequent cooling stages may further condensate the reactor output to extract liquids, such as water, which may be released through output 230 in the representation of FIG. 2. Cooler/separator 226 (or more than one cooler/separator) may have a collection area 234 for accumulation of precipitated material 232.

[0056] In one example, an output 238 of cooler/separator 226, with one or more than one stage, may convey a substantially gaseous output stream 240 of non-liquid and non-particulate output from reactor 202 to a scrubber 236. In scrubber 236, further cleaning of the output stream 240 occurs, such as to extract components such as gaseous H.sub.2S, nitrous components (NOx and/or NH.sub.3, for example), using chemical, catalytic and other known scrubbing techniques. In one example, scrubber 236 may be provided with a liquid drain 242 and a gas output 244.

[0057] Among the gaseous output from scrubber 236 may be an appreciable percentage of carbon dioxide CO.sub.2. As will be appreciated by those of ordinary skill, the composition of the outputs 242, 244 from scrubber 236 will depend upon the nature of the input feedstock 206, along with any carrier materials, such as carrier gases or liquids.

[0058] It will be understood by those of ordinary skill in the art having the benefit of this disclosure that the various process outputs, such as output(s) 230 from cooler/separator 226, and outputs 242 and 244 from scrubber 236, may produce materials (liquids, solids, or a combination thereof) requiring further processing for recapture, re-use, and/or disposal.

[0059] Turning to FIG. 3, there is shown a perspective view of a portion of the example processing system 200 of FIG. 2, including an example implementation of reactor 202. As shown in FIG. 3, input 204 is provided for introduction of input feedstock. It will be understood by those of ordinary skill having the benefit of the present disclosure that various physical implementations of input 204 may employed depending upon the composition and nature of the input feedstock. The example of FIG. 3 is generally adapted to receive a predominantly gaseous feedstock, whereas an implementation of system 200 may be provided for processing other input feedstock, such as fly ash or the like, having a more particulate composition. In such cases, the input feedstock may include, in addition to the material to be processed, one or more carriers, such as gaseous carriers, or liquid carriers. For example, fly ash may be mixed with water or other liquids and introduced through an input 204 in the form of a liquid slurry.

[0060] FIG. 3 shows first and second torch input lines 212 and 214, as well as steam input(s) 216. A valve 240 may be provided to control the supply of first torch fuel through inputs 212, and a valve 242 may be provided to control the supply of second torch fuel through inputs 214.

[0061] FIG. 4 is a top view of the portion of system 200 from FIG. 3. FIG. 5 is a side view of the portion of system 200 from FIG. 3. FIG. 6 is a side, cross-sectional view of the portion of system 200 from FIG. 3.

[0062] FIGS. 7 and 8 are side and side cross-sectional views, respectively, of a torch 208 such as depicted in the system 200 of FIGS. 2-6. As shown in FIGS. 7 and 8, torch 208 includes inputs 212 and 214. As noted above, in some examples input 212 may be for receiving a supply of a torch fuel, such as hydrogen (H.sub.2) or methane (CH.sub.4), and a second input 214 may be for receiving a supply of a second input, such as oxygen (O.sub.2).

[0063] As shown in FIGS. 7 and 8, fuel at input 212 passes through an inner tube 250 to a tee fitting 252 which receives input 214 introduced into a outer tube 254 that is coaxial with inner tube 250. Tubes 250 and 254 extend through a coupling 256 which, as is apparent in FIG. 5, for example, abuts the side wall of reactor 202. A distal portion 258 of torch 208 extends into reactor 202.

[0064] In accordance with one example, an arrangement of fittings and bushings designated collectively with reference numeral 260 is provided for adjusting the extent to which the distal tips 262 of tubes 250 and 254 extend into reactor 202. In one example, the spatial positioning of torch tip 262 may be adjusted to optimize the reactions taking place within combustion zone 211, and adjustment of the position of torch tip 262 may be desirable depending upon the nature and composition of input feedstock 206. It is known that a flame, such as a torch flame, has multiple different zones, such as an inner non-luminous zone, a dark zone a luminous zone, and a non-luminous veil; these different zones are characterized by different relative temperatures, and the presence and extent of one or more of these zones may be dependent upon the fuel being combusted as well as the combustion environment (e.g., the oxygen concentration). In one example, the extension of torch tips 262 may be adjusted to ensure that an incoming input feedstock stream 206 passes through optimal zones of each torch flame 210. To the extent that in some examples, input feedstock stream 206 may pass through or past a succession of torch flames 210, and each torch tip 262 may be adjusted independently to achieve optimal results.

[0065] At least one example has been described herein for the purposes of illustration. It is contemplated and to be explicitly understood that various substitutions, alterations, and/or modifications, including but not limited to any such implementation variants and options as may have been specifically noted or suggested herein, including inclusion of technological enhancements to any particular method step or system component discovered or developed subsequent to the date of this disclosure, may be made without departing from the technical and legal scope of the appended claims.