INTEGRATED PROCESS OF PYROLYSIS AND GASIFICATION OF WASTE AND THE DERIVATIVES THEREOF AND APPARATUS FOR THE IMPLEMENTATION THEREOF

Abstract

Process and apparatus that integrate continuously the processes of pyrolysis in a rotary drum at average temperatures of 300 to 500 C. and gasification in a moving-grate gasifier at average temperatures of 500 to 800 C. to produce a mixture of gases originating from the processes of pyrolysis and gasification of waste and the derivatives thereof. The mixture of gases called waste-derived combustible gases is continuously passed through a Venturi system or an exhaust system and can be directed to a system for combustion or treatment and separation of the combustible fractions for subsequent energy recovery. Waste in the form of powder, fines, slurries, pastes or liquids can be thermally treated individually or in blends with other waste such as municipal solid waste, commercial waste or industrial waste, with additional energy recovery.

Claims

1. Integrated pyrolysis and gasification process of waste and its derivatives comprising: step 1: feed the dosing feeder process (1.1) with waste and/or its derivatives; step 2: dose the waste and its derivatives to be inserted into the rotary kiln set (1.2); step 3: by action of gases from the exothermic reactions of the gasifier set (1.3) at a temperature of around 650 C. carry out the endothermic processes of pyrolysis of waste and its derivatives in the rotary kiln set (1.2); step 4: direct materials that were not pyrolyzed under the conditions imposed in the rotary kiln (1.2) to the gasifier (1.3) by rotating the kiln (1.2.1); step 5: move the material in process in the gasifier (1.3) by the advancing and retreating action of the moving grate sets (1.3.1.2), so that they are subjected to the partial oxidation reaction with atmospheric air, used as a gasifying agent, blown by the air blower (1.3.9) in an upward flow that passes through the holes (1.3.1.1.2) of the grates (1.3.1.1) and (1.3.1.2) to carry out the sub stoichiometric gasification combustion reactions, undergoing control of the predominantly sub stoichiometric reactions, pressure (1.5.1), temperature (1.5.2), and oxygen content (1.5.3) sensors are used; step 6: concomitant with step 5, the non-gasified materials in the gasification chamber (1.3) will be pushed through the moving grates (1.3.1.2) of the grate sections (1.3.1) to the ash extractor (1.3.8), as well as the fine materials that pass through the holes (1.3.1.1.2) in the grates go through the valves (1.3.5), through the screw conveyor (1.3.6), joining the rest of the ash in the conveyor (1.3.8), passing through the water or mechanical seal (1.3.7) to the outside of the gasifier (1.3) avoiding false air entering the gasifier (1.3); step 7: the gases produced in the gasifier (1.3) by the gasification reactions from the sub stoichiometric oxidation reaction of waste and its derivatives, will be drawn through the gas removal duct (1.1.5.4), passing through the interior of the rotary kiln (1.2.1), collaborating with the reaction in step 3 above; step 8: the gases produced in the rotary kiln set (1.2) by pyrolytic reactions from the decomposition of waste and their derivatives, together with the gases derived from the gasification processes carried out in the gasifier (1.3) are sucked into the waste removal duct gases (1.1.5.4); step 9: flow of the gas removal duct (1.1.5.4), which is caused by the system composed of the air blower (1.4.1) and Venturi (1.4.3), generating a Venturi effect pulling the gases; step 10: direct the gases drawn by the Venturi effect (1.4.3) to the entrance of the combustion chamber (1.4.8.1) tangentially to the chamber (1.4.8); step 11: concomitantly with step 10, inflate air flow, through a blower (1.4.6) and valve control (1.4.7), in the same rotational direction of the combustible gases derived from waste that enter tangentially into the combustion chamber (1.4.8) offering a minimum retention time of 1.5 seconds for gases inside the chamber at temperatures between 1,000 C. and 1,400 C.; step 12: use the thermal energy generated at the output (1.4.9).

2. Equipment integrated for pyrolysis and gasification of waste and its derivatives comprising: a set for feeding and dosing material and removing gases (1.1) a rotary pyrolysis set (1.2) a gasification set (1.3) and a combustion set of the gases generated (1.4).

3. Material feeder and doser and gas removal set (1.1), comprising: a) feeder (1.1.1); b) upper hopper (1.1.2); c) valve (1.1.3) to control the material input volume; d) lower hopper (1.1.4); e) pyrolysis rotary kiln feeder (1.1.5) comprising: body (1.1.5.1), with hopper (1.1.5.1.1) emergency valve (1.1.5.2); safety chimney (1.1.5.3); combustible gas outlet duct (1.1.5.4); emergency valve (1.1.5.5); and feeder/kiln seal (1.1.5.6).

4. Rotary pyrolysis kiln set (1.2), according to claim 2, characterized by comprising: a) rotary kiln (1.2.1) containing: a body (1.2.1.1); tracks (1.2.1.2); b) gear motor (1.2.2) to drive the kiln rotation; c) set of sensors (1.5) comprising: pressure transmitter (1.5.1); temperature transmitter (1.5.2); and O.sub.2 analyzer and transmitter (1.5.3).

5. Gasification set (1.3) according to claim 2, further comprising: a) sections containing: fixed grates (1.3.1.1) with: i) ramp (1.3.1.1.1); ii) horizontal holes (1.3.1.1.2), and; iii) sliding-fitting lower flap (1.3.1.1.3), and; iv) sliding-fitting top flap (1.3.1.1.4); moving grates (1.3.1.2) with: i) ramp; ii) horizontal holes, and; iii) sliding-fitting lower flap, and; iv) sliding-fitting top flap; b) hydraulic activation of the moving grates of the moving grates (1.3.1.2) of each section (1.3.1); c) hydraulic power plant with pump and reservoir (1.3.3); d) ash collectors (1.3.4); e) valves for ash collection (1.3.5); f) ash screw conveyor (1.3.6); g) water seal (1.3.7); h) Redler type conveyor (1.3.8); i) blower (1.3.9); j) blown air damper valves (1.3.10); k) gasifier/rotary kiln seal (1.3.11) l) level sensor/switch (1.3.12); m) sensor sets (1.5) on each section (1.3.1) comprising: n) pressure transmitters (1.5.1); o) temperature transmitters (1.5.2); p) O.sub.2 analyzers and transmitters (1.5.3); q) pressure transmitters (1.5.1) under each set of grates (1.3.1).

6. Generated gas combustion set (1.4), according to claim 2, characterized by comprising: a) extraction fan (1.4.1); b) Venturi (1.4.3); c) recovery gas supply line (1.4.4); d) pilot burner for startup (1.4.5); e) burner fan (1.4.6); f) damper valve (1.4.7); g) combustion chamber (1.4.8) comprising tangential inlet of produced gases (1.4.8.1); h) hot gas outlet (1.4.9); i) natural gas or LPG input line for startup (1.4.10); j) set of sensors (1.5) comprising: pressure transmitter (1.5.1); temperature transmitter (1.5.2); O.sub.2 analyzer and transmitter (1.5.3).

7. Integrated process for pyrolysis and gasification of waste and its derivatives, according to claim 1, characterized by presenting the first variant of the process comprising the following steps: step 1: feed the dosing feeder process (1.1) with waste and/or its derivatives; step 2: dose the waste and its derivatives to be inserted into the rotary kiln set (1.2); step 3: by action of gases from the exothermic reactions of the gasifier set (1.3) at a temperature of around 650 C. carry out the endothermic processes of pyrolysis of waste and its derivatives in the rotary kiln set (1.2); step 4: direct materials that were not pyrolyzed under the conditions imposed in the rotary kiln (1.2) to the gasifier (1.3) by rotating the kiln (1.2.1); step 5: move the material in process in the gasifier (1.3) by the advancing and retreating action of the moving grate sets (1.3.1.2), so that they are subjected to the partial oxidation reaction with atmospheric air, used as a gasifying agent, blown by the air blower (1.3.9) in an upward flow that passes through the holes in the grates (1.3.1.1) and (1.3.1.2) to carry out the sub stoichiometric combustion reactions of gasification, undergoing control of the predominantly sub stoichiometric reactions, pressure sensors are used (1.5.1), temperature (1.5.2), and oxygen content (1.5.3); step 6: concomitant with step 5, the non-gasified materials in the gasification chamber (1.3) will be pushed through the moving grates (1.3.1.2) of the grate sections (1.3.1) to the ash extractor (1.3.8), as well as the fine materials passing through the holes in the grates go through the valves (1.3.5), through the screw conveyor (1.3.6), joining the rest of the ash in the conveyor (1.3.8), passing through the water or mechanical seal (1.3.7) go outside the gasifier (1.3) avoiding false air entering the gasifier (1.3); step 7: the gases produced in the gasifier (1.3) by the gasification reactions from the sub stoichiometric oxidation reaction of waste and its derivatives, will be drawn through the gas removal duct (1.1.5.4), passing through the interior of the rotary kiln (1.2.1), collaborating with the reaction in step 3 above; step 8: the gases produced in the rotary kiln set (1.2) by pyrolytic reactions from the decomposition of waste and their derivatives, together with the gases derived from the gasification processes carried out in the gasifier (1.3) are sucked into the waste removal duct gases (1.1.5.4); step 9: flow of the gas removal duct (1.1.5.4) which is caused by the exhaust fan (1.4.11) pulling the gases; step 10: direct the gases drawn by the exhaust fan (1.4.11) to the combustion chamber entrance (1.4.8.1) tangentially to the chamber (1.4.8); step 11: concomitantly with step 10, blow the only air flow into the combustion chamber (1.4) through a blower (1.4.6) and valve control (1.4.7), in the same direction as the rotation of the combustible gases derived from waste that enter tangentially into the combustion chamber (1.4.8); step 12: make use of the thermal energy generated.

8. Equipment integrated for pyrolysis and gasification of waste and its derivatives, according to claim 2, characterized by the fact that it is presented as the first variant of the equipment comprising replacing the system with Venturi (1.4.3) and blower (1.4.1) by an exhaust fan (1.4.11) of hot gases with speed and flow control by frequency inverters, with combustion air being injected exclusively at the inlet of the combustion chamber, through the blower (1.4.6).

9. Integrated process for pyrolysis and gasification of waste and its derivatives, according to claim 1, characterized by presenting the second variant of the process comprising: step 1: feed the dosing feeder process (1.1) with waste and/or its derivatives; step 2: dose the waste and its derivatives to be inserted into the rotary kiln set (1.2); step 3: by action of gases from the exothermic reactions of the gasifier set (1.3) at a temperature of around 650 C. carry out the endothermic processes of pyrolysis of waste and its derivatives in the rotary kiln set (1.2); step 4: direct materials that were not pyrolyzed under the conditions imposed in the rotary kiln (1.2) to the gasifier (1.3) by rotating the kiln (1.2.1); step 5: move the material in process in the gasifier (1.3) by the advancing and retreating action of the moving grate sets (1.3.1.2), so that they are subjected to the partial oxidation reaction with atmospheric air, used as a gasifying agent, blown by the air blower (1.3.9) in an upward flow that passes through the holes in the grates (1.3.1.1) and (1.3.1.2) to carry out the sub stoichiometric combustion reactions of gasification, undergoing control of the predominantly sub stoichiometric reactions, pressure sensors are used (1.5.1), temperature (1.5.2), and oxygen content (1.5.3); step 6: concomitant with step 5, the non-gasified materials in the gasification chamber (1.3) will be pushed through the moving grates (1.3.1.2) of the grate sections (1.3.1) to the ash extractor (1.3.8), as well as the fine materials passing through the holes in the grates go through the valves (1.3.5), through the screw conveyor (1.3.6), joining the rest of the ash in the conveyor (1.3.8), passing through the water or mechanical seal (1.3.7) go outside the gasifier (1.3) avoiding false air entering the gasifier (1.3); step 7: the gases produced in the gasifier (1.3) by the gasification reactions from the sub stoichiometric oxidation reaction of waste and its derivatives, will be drawn through the gas removal duct (1.1.5.4), passing through the interior of the rotary kiln (1.2.1), collaborating with the reaction in step 3 above; step 8: the gases produced in the rotary kiln set (1.2) by pyrolytic reactions from the decomposition of waste and their derivatives, together with the gases derived from the gasification processes carried out in the gasifier (1.3) are sucked into the waste removal duct gases (1.1.5.4); step 9: flow of the gas removal duct (1.1.5.4) which is caused by the exhaust fan (1.4.11) pulling the gases; step 10: direct the gases drawn by the exhaust fan (1.4.11) to the treatment and separation system for combustible fractions sent to various energy use processes.

10. Equipment integrated for pyrolysis and gasification of waste and its derivatives, according to claim 2, characterized by the fact that it is presented as a second variant of the equipment comprising exhaust fan (1.4.1) and absence of a combustion chamber (1.4) and direction of the gases drawn by the exhaust fan (1.4.11) to the treatment and separation system for combustible fractions, and sent to various energy use processes.

Description

DESCRIPTION OF THE DRAWINGS

[0061] For a better understanding of the present invention, below is a detailed description of the invention making references to the attached drawings.

[0062] FIGS. 11 shows a general schematic drawing inside view in section of the complete set (1), in the best proposed solution, specifying its main parts.

[0063] FIG. 2shows a schematic drawing inside section of the feeding set (1.1).

[0064] FIG. 3shows a schematic drawing inside section of the rotating pyrolysis kiln set (1.2).

[0065] FIG. 4shows a schematic drawing inside section of the gasifier set (1.3).

[0066] FIG. 5shows a schematic drawing inside section of the combustor set (1.4).

[0067] FIG. 6shows a schematic drawing, inside view, of the location of the sensors of the invention.

[0068] FIG. 7shows a perspective of a section (1.3.1) of fixed (1.3.1.1) and moving (1.3.1.2) grates.

[0069] FIG. 8shows a perspective of a fixed grate (1.3.1.1) or moving grate (1.3.1.2).

[0070] FIG. 9shows a perspective of a fixed grate (1.3.1.1) or moving grate (1.3.1.2).

[0071] FIG. 10shows a general schematic drawing in sectional side view of the complete set (1), in the composition of the 1st variant, with exhaust fan (1.4.11), specifying its main parts.

[0072] FIG. 11shows a general schematic drawing in sectional side view of the complete set (1), in the composition of the 2nd variant, without the burner (1.4), specifying its main parts.

DETAILED DESCRIPTION OF THE INVENTION

[0073] The equipment of the present invention presents its functional technical composition comprising 04 basic parts: material feeding and dosing and gas removal set (1.1), rotary pyrolysis set (1.2), gasification set (1.3) and combustion set of generated gases (1.4).

[0074] The material feeder and doser and gas removal set (1.1) comprises: [0075] a) feeder (1.1.1); [0076] b) upper hopper (1.1.2); [0077] c) valve (1.1.3) to control the material input volume; [0078] d) lower hopper (1.1.4); [0079] e) pyrolysis rotary kiln feeder (1.1.5) comprising: [0080] body (1.1.5.1), with hopper (1.1.5.1.1) [0081] emergency valve (1.1.5.2); [0082] safety chimney (1.1.5.3); [0083] combustible gas outlet duct (1.1.5.4); [0084] emergency valve (1.1.5.5); [0085] feeder/rotary kiln seal (1.1.5.6);

[0086] The rotary pyrolysis kiln set (1.2) comprises: [0087] a) rotary kiln (1.2.1) comprising: [0088] body (1.2.1.1); [0089] tracks (1.2.1.2); [0090] b) gear motor (1.2.2) to drive the kiln rotation; [0091] c) set of sensors (1.5) comprising: [0092] pressure transmitter (1.5.1); [0093] temperature transmitter (1.5.2); [0094] O.sub.2 analyzer and transmitter (1.5.3), also known as lambda probe (2).

[0095] The gasification set (1.3) comprises: [0096] a) sections (1.3.1), comprising: [0097] fixed grates (1.3.1.1) with: [0098] i) ramp (1.3.1.1.1); [0099] ii) horizontal holes (1.3.1.1.2), and; [0100] iii) sliding-fitting lower flap (1.3.1.1.3), and; [0101] iv) sliding-fitting top flap (1.3.1.1.4); [0102] moving grates (1.3.1.2) with: [0103] i) ramp (1.3.1.1.1); [0104] ii) horizontal holes (1.3.1.1.2), and; [0105] iii) sliding-fitting lower flap (1.3.1.1.3), and; [0106] iv) sliding-fitting top flap (1.3.1.1.4); [0107] b) hydraulic drives (1.3.2) of the moving grates (1.3.1.2) of each section (1.3.1); [0108] c) hydraulic power plant with pump and reservoir (1.3.3); [0109] d) ash collectors (1.3.4); [0110] e) valves for ash collection (1.3.5); [0111] f) ash screw conveyor (1.3.6); [0112] g) water seal (1.3.7); [0113] h) Redler type conveyor (1.3.8); [0114] i) blower (1.3.9); [0115] j) blown air damper valves (1.3.10); [0116] k) gasifier/rotary kiln seal (1.3.11) [0117] l) level sensor/switch (1.3.12); [0118] m) sets of sensors (1.5) on each section (1.3.1) of the grate, comprising: [0119] n) pressure transmitters (1.5.1); [0120] o) temperature transmitters (1.5.2); [0121] p) O.sub.2 analyzers and transmitters (1.5.3), also known as lambda probe (2). [0122] q) pressure transmitters (1.5.1) under each section (1.3.1).

[0123] The combustion set of gases generated (1.4) comprises: [0124] a) extraction fan (1.4.1); [0125] b) Venturi (1.4.3); [0126] c) recovery gas supply line (1.4.4); [0127] d) pilot burner for startup (1.4.5); [0128] e) burner fan (1.4.6); [0129] f) damper valve (1.4.7); [0130] g) combustion chamber (1.4.8) comprising tangential inlet of produced gases (1.4.8.1); [0131] h) hot gas outlet (1.4.9); [0132] i) natural gas or LPG input line for startup (1.4.10); [0133] j) set of sensors (1.5) comprising: [0134] pressure transmitter (1.5.1); [0135] temperature transmitter (1.5.2); [0136] O.sub.2 analyzer and transmitter (1.5.3), also known as lambda probe (2).

[0137] During the operation of the equipment (1) there is a flow of solid, pasty and liquid fractions from the inlet set (1.1), passing to the kiln set (1.2), and, finally, to the gasifier set (1.3), where the coal residual is removed by Redler (1.3.8).

[0138] At the same time, there is a gas flow coming from the gasifier (1.3), passing through the pyrolysis set (1.2), and which is extracted through the duct (1.1.5.4) and directed to the combustor set (1.4).

[0139] As mainly seen in FIG. 1, the present invention integrates the processes of pyrolysis in a rotary kiln (1.2) and gasification on moving grates in the gasifier (1.3).

[0140] The equipment components (1) are built with materials suitable for each phase of the overall process, according to temperature, humidity, electrochemical corrosivity and abrasiveness.

[0141] It is a process that can be operated electronically through responses to pressure sensors (1.5.1), temperature (1.5.2), and oxygen content (1.5.3), acting to control the speed of the gearmotor (1.2.2) of rotation of the rotary kiln (1.2.1), speed of advance and retreat of the moving grates (1.3.1.2) of the sets of grates (1.3.1) of the gasifier, timer of the mechanical valves (1.1.3) of input of materials, speed of the ash extraction Redler (1.3.8), speed/flow of air blower (1.4.1) in the Venturi system (1.4.3), speed/flow of air in the gasification system (1.3) by control of the blower (1.3.9) and valves (1.3.10), air flow in the blower (1.4.6) of the combustion chamber (1.4), the entire process being linked to the safety valve system (1.1.5.1), (1.1.5.2) and (1.4.7).

[0142] As better described later in the 1st variant of the equipment (1), instead of controlling the blower (1.4.6), control is carried out over the gas exhaust fan (1.4.11).

[0143] The basic instrumentation, seen in FIG. 6, comprises: [0144] a) pressure transmitter (1.5.1); [0145] b) temperature transmitter (1.5.2); [0146] c) O.sub.2 analyzer and transmitter (1.5.3), also known as lambda probe (2).

[0147] Such sensors will be controlled by a control loop that will control the frequency inverters of the fans and exhaust fans (1.4.1), (1.4.11), (1.3.9) and (1.4.6), the frequency inverter of the gearmotor (1.2.2) that drives the rotation of the kiln (1.2.1), valves (1.1.3), (1.1.5.3), (1.1.5.5), (1.3.5), (1.3.10) and (1.4.7), and the movement of the moving grates (1.3.1.2) by the hydraulic unit (1.3.3) managing the entire operation of the equipment (1).

[0148] In the material feeder and doser and gas removal set (1.1) the feeder (1.1.1); It can be of different types, such as the belt represented in the figures, or claws, or mugs, among others.

[0149] The upper hopper (1.1.2) acts as a funnel receiving the material to be processed, which then meets the valve (1.1.3) to control the material input volume.

[0150] The lower hopper (1.1.4) directs the dosed material to the feeder inlet of the rotary pyrolysis kiln (1.1.5).

[0151] The feeder of the rotary pyrolysis kiln (1.1.5) has the body (1.1.5.1) of several functions, which are to offer the material to be processed the path to the set (1.2) or through the hopper (1.1.5.1.1), and the path of counterflow gases to the outlet (1.1.5.4) through the valve (1.1.5.5).

[0152] Attached to the body (1.1.) is also the safety valve (1.1.5.2), which directs, in cases of emergencies/abrupt stops, the gases to the chimney (1.1.5.3).

[0153] The feeder/rotary kiln seal (1.1.5.6) in the region of separation between the moving part of the kiln (1.2.1) and the fixed part of the body (1.1.5.1) prevents false air from entering the system.

[0154] In the heat production process of this invention, two distinct methods of treating waste and their derivatives are continuously incorporated, namely, pyrolysis and gasification, generating gases to be burned in a combustion chamber (1.4).

[0155] In this way, it is possible to solve the problems that limit such processes to a comprehensive treatment of waste and its derivatives with energy recovery. The simple pyrolysis process is limited by the high coal content it produces in addition to the gases and oils it produces in the gaseous state.

[0156] In the integrated process given by the invention the gaseous fraction of the pyrolytic processes in set (1.2) and gasification in set (1.3) are pulled, by the action of the Venturi (1.4.3), to the duct (1.1.5.4), and then directed to the combustion chamber set (1.4), with the coal being directed to the gasification chamber set (1.3).

[0157] Through the invention in the pyrolysis process in a rotary kiln (1.2) it is possible to process and pyrolyze fine materials, powders, sludges, pastes and liquids, including blends of these materials with municipal, commercial and industrial solid waste.

[0158] The rotary kiln set (1.2) performs the function of pyrolysis of the material in process, which, for this purpose, has its body (1.2.1.1) rotated, by the gear motor (1.2.2), on the tracks (1.2.1.2).

[0159] As shown in FIG. 6, providing data for equipment automation (1), internally in the kiln (1.2.1), there is a set of sensors (1.5) comprising a pressure transmitter (1.5.1), temperature transmitter (1.5.2), O.sub.2 analyzer and transmitter (1.5.3), also known as lambda probe (2).

[0160] In this invention, the dosing feeder (1.1) feeds the rotary kiln (1.2) for the pyrolysis reactions, where the seal (1.1.5.6) of the feeder/doser set (1.1) and the sealing (1.3.11) of the gasifier set (1.3) guarantee the absence of false air passage and gas leakage between moving parts of the rotary kiln (1.2) and those fixed on both sides of it.

[0161] The gear motor (1.2.2) determines the rotation speed of the rotary kiln (1.2.1) which provides the revolving and movement of the material so that good pyrolysis occurs, and the material is sent to the gasifier set (1.3).

[0162] Conventional gasification processes using moving grates do not allow processing certain materials due to their physical forms, such as fine materials, powders, sludges, pastes and liquids.

[0163] However, in the invention the gasification process on moving grates given in the gasification set (1.3) can process the ashes from the pyrolysis process on grates with transverse holes.

[0164] This way, the processes complement each other by taking on tasks not performed by the other.

[0165] The gasification set (1.3) comprises sets of grate sections (1.3.1), where, in the direction of material flow, the odd lines are with fixed grates (1.3.1.1) and the even lines are with moving grates (1.3.1.2).

[0166] The number of grates lines (1.3.1.1) and (1.3.1.2) for each independent section (1.3.1), as well as the number of grates per even or odd line, depends on the processing capacity or size of each equipment.

[0167] In the present invention, it is possible to control, individually for each section (1.3.1) of grates, both the advance and retreat speed of the moving grates (1.3.1.2), as well as the time between each activation, according to the responses to the data from the sensor sets (1.5) located on each set.

[0168] The movement of the grate sets (1.3.1.2) is done by hydraulic actuators (1.3.2), these can be cylinders or hydraulic motors, where propulsion is offered by the hydraulic unit with pump and reservoir (1.3.3).

[0169] The moving grates (1.3.1.2) move with the upper sliding-fitting flaps (1.3.1.1.4) sliding over the adjacent lower sliding-fitting flaps (1.3.1.1.3), providing the necessary sealing.

[0170] During movement, the material descends over the grates, mainly through the ramps (1.3.1.1.1), while it is blown by the air injected through the holes (1.3.1.1.2).

[0171] Also in the gasification set (1.3) there are ash collectors (1.3.4) residual from the process, which, like hoppers, direct such ash to the ash collection valves (1.3.5), ash conveyor screw (1.3.6), and finally, using a Redler-type conveyor (1.3.8), out of the equipment (1).

[0172] The Redler type conveyor (1.3.8) has its lower part covered by a water seal (1.3.7) preventing false air from entering the equipment (1).

[0173] The air blown into the gasifier (1.3) is controlled by a frequency inverter that operates the blower (1.3.9) and drives the blown air damper valves (1.3.10).

[0174] The gasifier/rotary kiln seal (1.3.11) prevents false air from entering.

[0175] The level sensor/switch (1.3.12) maintains the seal level at such a height that it does not allow false air to enter through the gasifier Redler (1.3.8) (1.3).

[0176] As shown in FIG. 7, providing data for equipment automation (1), internally of the gasifier (1.3), above each grate section (1.3.1), there is a set of sensors (1.5) comprising a pressure transmitter (1.5.1), temperature transmitter (1.5.2), 02 analyzer and transmitter (1.5.3), also known as lambda probe (2).

[0177] Below each grate section (1.3.1) there is a pressure sensor (1.5.1), also providing data for equipment automation (1). Based on the signals from these sensors, the blown air damper valves (1.3.10) are opened, the purpose of which is to maintain constant pressure at these points.

[0178] In the present invention, the endothermic pyrolysis process that occurs in set (1.2), and the consequent thermal decomposition of waste and its derivatives will be thermally fed with the heat of the gases produced in the exothermic gasification reactions of set (1.3).

[0179] This is possible by passing the gasification gas flow, which is heated to an average temperature of 650 C. (between 50 and 800 C.), through the rotary kiln (1.2.1), which, when rotating, promotes contact between the materials to be processed with this heated gas.

[0180] To make this possible, the gas removal duct (1.1.5.4), best seen in FIG. 2, will be arranged next to the material inlet in the rotary kiln (1.2.1), so that the flow of gases is countercurrent in relation to solid, pasty and liquid material.

[0181] Controlling the rotation speed of the kiln (1.2.1) and controlling the amount of material to be processed must maintain the temperature of the mixture of gasification gases from set (1.3) plus pyrolytic gases from set (1.2) at an average value 400 C. (between 30 and 500 C.), to avoid condensation of pyrolytic gases.

[0182] The O.sub.2 measuring cell by lambda probe (1.5.3) interconnected to the operating system, allows control and guarantees that there will be no oxygen available for complete combustion in the pyrolysis chamber (1.2).

[0183] The internal working temperature of the rotary kiln (1.2.1) for pyrolysis reactions should be around 400 C. on average, in the gasifier (1.3) the average internal working temperature will be around 650 C.

[0184] The control of sub stoichiometric reactions takes place by blower air insufflation (1.3.9), which is controlled by the temperature, pressure and oxygen concentration given by the sensors (1.5) above each grate section (1.3.1) and by the pressure (1.5.1) below each section (1.3.1) of grate.

[0185] The control of the gas flow in the gasifier and in the rotary kiln will be done by the air blower frequency inverter (1.4.1) coupled to the duct so that the Venturi effect is created in the Venturi (1.4.3).

[0186] The control will be done by the pressure above the grates (1.3.1) of the gasification chamber, which must be below atmospheric pressure to guarantee a vacuum process.

[0187] The Venturi effect guarantees the flow of gases and pressure throughout the process, as well as providing the torsional combustor (1.4) with a mixture of combustible gases from the pyrolysis and gasification processes plus the oxidizing atmospheric air from the blower (1.4.6).

[0188] The blower (1.4.6) is controlled by the valve (1.4.7) together with a frequency inverter.

[0189] In the invention a residue is generated which is called process ash.

[0190] These ashes contain the inorganic fraction present in the waste and its derivatives. The composition of the ash and its quantity will depend on the type of waste to be processed and must be characterized/classified and disposed of appropriately.

[0191] The gasifier (1.3) has the function of conditioning the material from the rotary kiln (1.2) for sub stoichiometric reactions to produce gas operating at average temperatures of 650 C., and, for this purpose, it is coated with ceramic material to maintain conditions at these temperatures and not be attacked by corrosive gases.

[0192] The fixed (1.3.1.1) and moving (1.3.1.2) grates of the gasifier (1.3) are made of cast iron with special alloys and have the function of pushing the materials.

[0193] According to FIG. 7, the odd rows of grates are fixed (1.3.1.1) and the even rows are moving (1.3.1.2) with forward and backward movement in the direction of material flow.

[0194] As shown in FIGS. 7, 8 and 9, the individual grates that move the materials to be heat treated during the exothermic processes, have on their upper face a recess (1.3.1.1.1) in the form of a descending ramp, outside the travel area, that is, outside the contact area between the moving and fixed grate during the movement of the grate set.

[0195] This recess (1.3.1.1.1) allows transverse holes (1.3.1.1.2) to be made in the direction of passage of materials, reducing the possibility of passage of fine materials to the bottom of the gasifier (1.3) and/or obstruction of the holes, and also benefiting the control of the air flow given by the blower (1.3.9) for the oxidation reactions on the grate.

[0196] As shown in FIGS. 8 and 9, the individual grates have flaps and recesses on the side edges of the male (1.3.1.1.3) and female (1.3.1.1.4) type, in order to prevent the passage of fine materials through the gaps and also do not allow air flow.

[0197] In FIG. 7 it is possible to see the assembly of the grate set (1.3.1), with the individual grates side by side and the side flaps (1.3.1.1.3) and (1.3.1.1.4) overlapping.

[0198] As previously stated, the number of grate lines (1.3.1.1) and (1.3.1.2) for each independent section (1.3.1), as well as the number of grates per even or odd line, depends on the processing capacity or size of each equipment, therefore, each section (1.3.1) of grates can be activated individually, according to the responses to the sets of sensors (1.5.) located on each set of grates.

[0199] The movement of the moving grates (1.3.1.2) of each section can be varied in terms of the speed of advancement and retreat as well as the time between movement activations.

[0200] The ash collectors (1.3.4) of the gasifier (1.3) have the purpose of removing ash, directing it to valves (1.3.5) that control the ash output flow.

[0201] When the valves (1.3.5) are opened, the ash falls onto a collector (1.3.6) with a screw conveyor, which directs it to the entrance of a Redler-type conveyor (1.3.8) submerged by a water seal with a level (1.3.7).

[0202] In this way, the sealing of the ash extraction is done by a water seal, ensuring that there is no false air entry.

[0203] The blower (1.3.9) is located below the grate (1.3.1) and ensures the appropriate amount of air in each section of the grate through the damper valves (1.3.10), in order to maintain controlled sub stoichiometric reactions in each section of the gasifier (1.3).

[0204] The gas removal duct (1.1.5.4) carries gases from the pyrolysis and gasification processes towards the combustion set (1.4).

[0205] For this flow to occur properly, the air blower (1.4.1) is controlled by a frequency inverter.

[0206] The air from the blower (1.4.1) goes to a Venturi (1.4.3) that drags the gases from the duct (1.5.5.4) towards the combustion set (1.4).

[0207] The duct closing safety valve (1.1.5.5) acts to close the duct (1.1.5.4) in case of sudden stop/emergency. In these cases of sudden stop, the safety chimney (1.1.5.3) has the purpose of evacuating the pyrolysis and gasification chambers, with the concomitant action of the chimney opening safety valve (1.1.5.2).

[0208] The combustion set (1.4) aims to condition perfect combustion of gases produced in the pyrolysis and gasification processes. It is coated with ceramic material in order to withstand temperature conditions of up to 1,400 C.

[0209] The pilot burner (1.4.5) operates only for initial heating of the chamber (1.4.8) or to act in the event of a flame extinguishing emergency.

[0210] The air blowers (1.4.6) serve to supply the concentration of air necessary for combustion, this concentration being controlled by the valve (1.4.7) and frequency inverters.

[0211] The gases produced (from pyrolysis and gasification) have a tangential entry (1.4.8.1) into the combustion chamber (1.4.8), which has this arrangement so that such gases are directed to the internal walls of the combustor in a torsional movement or swirl and, consequently, increase turbulence to increase burning efficiency.

[0212] The hydraulic control unit (1.3.3) has the purpose of activating the moving grates, a set of registers with pneumatic actuators.

[0213] The valves (1.3.10) have the function of opening and closing the upward air flow in each section of the gasifier.

[0214] Therefore, the invention receives waste and its derivatives, carries out the pyrolysis and gasification process sequentially, producing a mixture of gases with combustible contents, which we can now call Derived Combustible Gases of Waste (DCGW).

[0215] These gases can be submitted directly to the combustion set (1.4) and produce hot gases at temperatures around 1,200 C.

[0216] To control combustion reactions in the combustion chamber (1.4.8), pressure (1.5.1), temperature (1.5.2), and oxygen content (1.5.3) sensors are used.

[0217] The combustion chamber (1.4) is sized in terms of diameter and length so that it obtains a minimum retention time of 1.5 seconds for the gases inside the chamber at temperatures between 1,000 C. and 1,400 C.

[0218] These combustion gases can be used in different ways, the most common being in industrial dryers, in industrial steam production, in Rankine cycle electrical energy production, or others that can be compatible with these characteristics.

[0219] The integrated pyrolysis and gasification PROCESS of waste and its derivatives is characterized by comprising the following steps: [0220] a) step 1: feed the dosing feeder process (1.1) with waste and/or its derivatives. [0221] b) step 2: dose the waste and its derivatives to be inserted into the rotary kiln set (1.2); [0222] c) step 3: by action of gases from the exothermic reactions of the gasifier set (1.3) at a temperature of around 650 C. carry out the endothermic processes of pyrolysis of waste and its derivatives in the rotary kiln set (1.2); [0223] d) step 4: direct materials that were not pyrolyzed under the conditions imposed in the rotary kiln (1.2) to the gasifier (1.3) by rotary the kiln (1.2.1); [0224] e) step 5: move the material in process in the gasifier (1.3) by the advancing and retreating action of the moving grate sets (1.3.1.2), so that they are subjected to the partial oxidation reaction with atmospheric air, used as a gasifying agent, blown by the air blower (1.3.9) in an upward flow that passes through the holes in the grates (1.3.1.1) and (1.3.1.2) to carry out the sub stoichiometric gasification combustion reactions, undergoing control of the predominantly sub stoichiometric reactions, pressure sensors are used (1.5.1), temperature (1.5.2), and oxygen content (1.5.3); [0225] f) step 6: concomitant with step 5, the non-gasified materials in the gasification chamber (1.3) will be pushed through the moving grates (1.3.1.2) of the grate sections (1.3.1) to the ash extractor (1.3.8), as well as The fine materials passing through the holes in the grates go through the valves (1.3.5), through the screw conveyor (1.3.6), joining the rest of the ash in the conveyor (1.3.8), passing through the water or mechanical seal (1.3.7) go outside the gasifier (1.3) avoiding false air entering the gasifier (1.3); [0226] g) step 7: the gases produced in the gasifier (1.3) by the gasification reactions from the substoichiometric oxidation reaction of waste and its derivatives, will be drawn through the gas removal duct (1.1.5.4), passing through the interior of the rotary kiln (1.2.1), collaborating with the reaction in step 3 above; [0227] h) step 8: the gases produced in the rotary kiln set (1.2) by pyrolytic reactions from the decomposition of waste and their derivatives, together with the gases derived from the gasification processes carried out in the gasifier (1.3) are sucked into the waste removal duct gases (1.1.5.4); [0228] i) step 9: flow of the gas removal duct (1.1.5.4) which is caused by the system composed of the air blower (1.4.1), Venturi (1.4.3), which generates a Venturi effect pulling the gases. [0229] j) step 10: direct the gases drawn by the Venturi effect (1.4.3) to the entrance of the combustion chamber (1.4.8.1) tangentially to the chamber (1.4.8); [0230] k) step 11: concomitantly with step 10, inflate air flow, through a blower (1.4.6) and valve control (1.4.7), in the same rotational direction of the combustible gases derived from waste that enter tangentially into the combustion chamber (1.4.8) offering a minimum retention time of 1.5 seconds for gases inside the chamber at temperatures between 1,000 C. and 1,400 C.; [0231] l) step 12: make use of the thermal energy generated.

Description of the 1st Solution Variant (Process)

[0232] The 1st variant of the process is characterized by the fact that it comprises: [0233] a) step 1: feed the dosing feeder process (1.1) with waste and/or its derivatives; [0234] b) step 2: dose the waste and its derivatives to be inserted into the rotary kiln set (1.2); [0235] c) step 3: by action of gases from the exothermic reactions of the gasifier set (1.3) at a temperature of around 650 C. carry out the endothermic processes of pyrolysis of waste and its derivatives in the rotary kiln set (1.2); [0236] d) step 4: direct materials that were not pyrolyzed under the conditions imposed in the rotary kiln (1.2) to the gasifier (1.3) by rotary the kiln (1.2.1); [0237] e) step 5: move the material in process in the gasifier (1.3) by the advancing and retreating action of the moving grate sets (1.3.1.2), so that they are subjected to the partial oxidation reaction with atmospheric air, used as a gasifying agent, blown by the air blower (1.3.9) in an upward flow that passes through the holes in the grates (1.3.1.1) and (1.3.1.2) to carry out the sub stoichiometric combustion reactions of gasification, undergoing control of the predominantly sub stoichiometric reactions, pressure sensors are used (1.5.1), temperature (1.5.2), and oxygen content (1.5.3); [0238] f) step 6: concomitant with step 5, the non-gasified materials in the gasification chamber (1.3) will be pushed through the moving grates (1.3.1.2) of the grate sections (1.3.1) to the ash extractor (1.3.8), as well as The fine materials passing through the holes in the grates go through the valves (1.3.5), through the screw conveyor (1.3.6), joining the rest of the ash in the conveyor (1.3.8), passing through the water or mechanical seal (1.3.7) go outside the gasifier (1.3) avoiding false air entering the gasifier (1.3); [0239] g) step 7: the gases produced in the gasifier (1.3) by the gasification reactions from the sub stoichiometric oxidation reaction of waste and its derivatives, will be drawn through the gas removal duct (1.1.5.4), passing through the interior of the rotary kiln (1.2.1), collaborating with the reaction in step 3 above; [0240] h) step 8: the gases produced in the rotary kiln set (1.2) by pyrolytic reactions from the decomposition of waste and their derivatives, together with the gases derived from the gasification processes carried out in the gasifier (1.3) are sucked into the waste removal duct gases (1.1.5.4); [0241] i) step 9: flow of the gas removal duct (1.1.5.4) which is caused by the exhaust fan (1.4.11) pulling the gases; [0242] j) step 10: direct the gases drawn by the exhaust fan (1.4.11) to the combustion chamber entrance (1.4.8.1) tangentially to the chamber (1.4.8); [0243] k) step 11: concomitantly with step 10, blow the only air flow into the combustion chamber (1.4) through a blower (1.4.6) and valve control (1.4.7), in the same direction as the rotation of the combustible gases derived from waste that enter tangentially into the combustion chamber (1.4.8); [0244] l) step 12: make use of the thermal energy generated.

Description of the 1st Solution Variant (Equipment)

[0245] FIG. 6 shows the first variant of the invention here called equipment (2).

[0246] In the 1st variant, equipment (2), replacing the system with Venturi (1.4.3) and blower (1.4.1), a system is used with the hot gas exhaust fan (1.4.11) with speed and flow control by frequency inverters

[0247] The exhaust fan (1.4.11) maintains constant pressure in the integrated pyrolysis and gasification processes. In this case, the combustion air injection will be made exclusively at the combustion chamber inlet, by the blower (1.4.6).

Description of the 2nd Solution Variant (Process)

[0248] The 2nd variant of the process is characterized by the fact that it comprises: [0249] a) step 1: feed the dosing feeder process (1.1) with waste and/or its derivatives; [0250] b) step 2: dose the waste and its derivatives to be inserted into the rotary kiln set (1.2); [0251] c) step 3: by action of gases from the exothermic reactions of the gasifier set (1.3) at a temperature of around 650 C. carry out the endothermic processes of pyrolysis of waste and its derivatives in the rotary kiln set (1.2); [0252] d) step 4: direct materials that were not pyrolyzed under the conditions imposed in the rotary kiln (1.2) to the gasifier (1.3) by rotary the kiln (1.2.1); [0253] e) step 5: move the material in process in the gasifier (1.3) by the advancing and retreating action of the moving grate sets (1.3.1.2), so that they are subjected to the partial oxidation reaction with atmospheric air, used as a gasifying agent, blown by the air blower (1.3.9) in an upward flow that passes through the holes in the grates (1.3.1.1) and (1.3.1.2) to carry out the sub stoichiometric combustion reactions of gasification, undergoing control of the predominantly sub stoichiometric reactions, pressure sensors are used (1.5.1), temperature (1.5.2), and oxygen content (1.5.3); [0254] f) step 6: concomitant with step 5, the non-gasified materials in the gasification chamber (1.3) will be pushed through the moving grates (1.3.1.2) of the grate sections (1.3.1) to the ash extractor (1.3.8), as well as The fine materials passing through the holes in the grates go through the valves (1.3.5), through the screw conveyor (1.3.6), joining the rest of the ash in the conveyor (1.3.8), passing through the water or mechanical seal (1.3.7) go outside the gasifier (1.3) avoiding false air entering the gasifier (1.3); [0255] g) step 7: the gases produced in the gasifier (1.3) by the gasification reactions from the sub stoichiometric oxidation reaction of waste and its derivatives, will be drawn through the gas removal duct (1.1.5.4), passing through the interior of the rotary kiln (1.2.1), collaborating with the reaction in step 3 above; [0256] h) step 8: the gases produced in the rotary kiln set (1.2) by pyrolytic reactions from the decomposition of waste and their derivatives, together with the gases derived from the gasification processes carried out in the gasifier (1.3) are sucked into the waste removal duct gases (1.1.5.4); [0257] i) step 9: flow of the gas removal duct (1.1.5.4) which is caused by the exhaust fan (1.4.11) pulling the gases; [0258] j) step 10: direct the gases drawn by the exhaust fan (1.4.11) to the treatment and separation system for combustible fractions and sent to various energy use processes.

Description of the 2nd Solution Variant (Equipment)

[0259] As shown in FIG. 7, the second variant is configured by the equipment (3) not combusting gases directly at the system outlet with Venturi (1.4.3) of the best proposed solution or at the exhaust fan outlet (1.4.11) of the first variant.

[0260] In the 2nd variant, equipment (3), combustible gases derived from waste will be sent to the outlet (1.4.15) by an exhaust fan (1.411) controlled by a frequency inverter.

[0261] These combustible gases derived from waste must be used in a treatment and separation system for combustible fractions and sent to various energy recovery processes.

[0262] This is another possibility of using Combustible Gases Derived from Waste (CGDW), where they are subjected to treatment and separation processes into combustible fractions such as oils and gases. The treatment must be in accordance with the uses, such as burning in engines, direct burning in gas turbines, obtaining fuel oils, among others.

[0263] The present invention is from the waste treatment and energy recovery industry sector.