Mobile apparatus for carbon-containing materials including biohazard wastes gasification by thermal decomposition and conversion into a liquid fuels.
20170355909 · 2017-12-14
Inventors
Cpc classification
C10K1/12
CHEMISTRY; METALLURGY
C10J2300/0906
CHEMISTRY; METALLURGY
C10K3/04
CHEMISTRY; METALLURGY
C10J2300/0946
CHEMISTRY; METALLURGY
B09B3/45
PERFORMING OPERATIONS; TRANSPORTING
Y02P20/10
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
C10J2200/31
CHEMISTRY; METALLURGY
Y02W30/20
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
C10K1/20
CHEMISTRY; METALLURGY
Y02E50/30
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
C10G2300/4068
CHEMISTRY; METALLURGY
International classification
C10G2/00
CHEMISTRY; METALLURGY
B09B3/00
PERFORMING OPERATIONS; TRANSPORTING
Abstract
The present invention relates to a method for gasification of carbon-containing materials including biohazard wastes, and more specifically, to a method for gasification of carbon-containing materials which allows an increase in carbon efficiency and a reduction in carbon dioxide emission, comprising the steps of: biohazard wastes grinding and sterilization, mix with carbon-containing materials for the gasification; and catalytic production of diesel fuel. A system having a movable platform including: material preparation block, gasification and catalytic of diesel fuel production reactors which are structurally and functionally integrated. In the practice of the process, a mixture of carbon-containing materials, a compressed air feed and process steam is fed to the gasifier to produce a synthesis gas. The synthesis gas is fed to the Fischer-Tropsch reactor where it is catalytically reacted to produce heavy hydrocarbons. The outlet from the Fischer-Tropsch reactor is separated into water, a low heating value tail gas, and the desired hydrocarbon liquid product. The water is pressurized and heated to generate process steam. The system further includes a plurality of heat exchangers that enable heat to be recovered from the outlet of the gasifier. The recovered heat is used to make the process steam as well as to preheat the hydrocarbon mix before it is fed to the gasifier and preheat the synthesis gas before it is fed to the Fischer-Tropsch reactor. The method of the present invention greatly increases carbon efficiency and reduces the generation of carbon dioxide.
Claims
1. A carbon-containing materials to liquids process comprising the steps of: a. transporting a movable platform comprising a material preparation unit, synthesis gas production unit, a synthetic crude production unit, and a product clean up unit to a location at or near carbon-containing materials containing reserve; b. receiving carbon-containing materials from the reserve and biohazard wastes from the appropriate source; c. shredding said waste, and transporting said shredded waste into a neutralization chamber; d. neutralizing biohazardous waste with the super-heated steam and transporting neutralized said wastes into a mixing chamber; e. mixing said neutralized wastes and carbon-containing materials; f. converting the said mix into a synthesis gas in the synthesis gas production unit; g. converting synthesis gas produced in step f by a Fischer Tropsch (F-T) process into a finished end-user product.
2. The process of claim 1 wherein use of water gas shift with, and without electrolysis in the syngas stream to attain gas equilibrium, and enrich syngas with additional hydrogen.
3. The process of claim 1 wherein the synthesis gas produced in step f has an H.sub.2/CO ratio equal to or greater than 2.
4. The process of claim 1 further including the step of increasing the H.sub.2/CO ratio of the synthesis gas produced by the gasification of the said mix by the water-gas shift reaction.
5. The process of claim 1 further including the step of converting synthesis gas produced by steps f to hydrocarbon products by Fischer-Tropsch synthesis.
6. The process of claim 1 wherein the feed to the said mix liquefaction of step g includes hydrogen from the synthesis gas produced by steps f.
7. The process of claim 1 wherein the movable platform further comprises a utilities unit operationally connected to the system, wherein the utilities system comprises a cooling water system and industrial electrical power connection.
8. The process of claim 1 wherein the neutralizing biohazardous waste said in step c comprising carrying out the steps of: a. shearing biohazardous waste in a closed container having an internal wall with a device to expose an interior portion of the biohazardous waste to direct contact with a high-pressure steam; b. generating and filling the container with the high-pressure steam having a temperature between 150° C. and 170° C. to sterilize the sheared biohazardous waste, the internal wall of the container and the device to expose the interior portion of the biohazardous waste within the container.
9. A process according to claim 1, wherein the sheared biohazardous waste is sterilized by the high-pressure steam for at least 20 minutes.
10. A process according to claim 1, wherein the other device is a means for crushing biohazardous waste.
11. A process according to claim 1, wherein the air is sterilized by at least one means selected from the group consisting of filtering means, heating means and chemical oxidation means.
12. A system for disposing of biohazardous waste having non-exposed interior portions, comprising a pressure container having at least one top opening portion with a means for closing said at least one top opening providing for an airtight closing, a means for crushing biohazardous waste which is capable of shearing the biohazardous waste to expose the interior portions of the biohazardous waste to direct contact with high-pressure steam, a means for generating steam below said crushing means, said steam generating means comprising water filled in a lower portion of the pressure container and a heater provided within the water, a means for exhausting air out of the pressure container and a means for sterilizing the exhausted air, wherein the means for crushing biohazardous waste and the means for generating steam are positioned within the pressure container.
13. A system according to claim 11, wherein the pressure container has an opening formed in an upper portion of the pressure container which is an inlet for feeding biohazardous waste therein and another opening formed in a lower portion of the pressure container which is an outlet for discharging the sheared and sterilized biohazardous waste.
14. A system according to claim 11, wherein the pressure container has a movable receiving pan for receiving sheared biohazardous waste, the receiving pan being positioned above the water and having a plurality of pores at least in a bottom thereof.
15. A system according to claim 11, wherein the means for exhausting air comprises a pipe communicating with the pressure container and an air-sucking pump connected to the pipe.
16. A system according to claim 11, wherein the means for sterilizing the exhausted air is at least one means selected from the group consisting of a filtering means, a heating means and a chemical oxidation means, positioned in a pipe connecting the pressure container and a sucking pump.
17. A system according to claim 11, wherein the pressure container further has a means for jetting water to cool the steam.
18. A method of gasifying a carbon-containing material said in step e, comprising of: 1. reacting the carbon-containing material with steam in presence of a catalyst thus producing a gas product including CO, CO.sub.2, CH.sub.4, H.sub.2O and H.sub.2; 2. thermally decomposing CH.sub.4 generated in stage 1 into C and H.sub.2; and 3. converting CO.sub.2 generated in stage 1 into CO using the product of stages 2 and 3
19. The method of claim 17, further comprising recirculating at least a part of carbon generated in 2 to 3 of claim 17 which gasifies the carbon-containing material.
20. The method of claim 17, further comprising recirculating H.sub.2 and CO generated in 2 to 3 of claim 17.
21. The method of claim 18, further comprising recirculating H.sub.2 and CO generated in 1 to 3 of claim 17.
22. The method of claim 17, wherein 3 is carried out using any one selected from among a reverse water-gas shift reaction, a hydrogenation reaction, a CO.sub.2 reforming reaction, and a C—CO.sub.2 gasification reaction.
23. The method of claim 17, wherein the carbon-containing material is coal, low quality brown coal, coal chips and dust, biomass, waste, heavy oil, or petroleum coke, crude oil, used tires, municipal and biohazardous wastes.
24. The method of claim 17 yields 1-1.5 m.sup.3 of said synthesis gas per 1 kilogram of low quality brown coal and municipal wastes.
25. The process of claim 1 wherein the said synthesis gas reacting in the presence of a hydrocarbon synthesis catalyst to produce heavier hydrocarbons.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION OF THE INVENTION
[0033] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. For the purposes of the present invention, the term syngas (or synthesis gas) refers to the product of a gasification process, and may include carbon monoxide, hydrogen, and carbon dioxide, in addition to other gaseous components such as methane and water.
[0034] In the Figures,
[0035] As shown in
[0036]
[0037]
[0038]
CH.sub.xO.sub.y+wH.sub.2O+m0.sub.2+3.76mN.sub.2->aH.sub.2+bCO+CCO.sub.2+dH.sub.2O+eCH.sub.4+fN,+gC
where w is the amount of water per mole of waste material, m is the amount of O2 per mole of waste, a, b, c, d, e, f and g are the coefficients of the gaseous products and soot (all stoichiometric coefficients in moles). The detailed main reactions are as follows:
CH.sub.4+H.sub.2O->CO+3H.sub.2 (CH4 decomposition-endothermic)
CO+H.sub.2O->CO.sub.2+H.sub.2 (water gas shift reaction-exothermic)
C+H.sub.2O->CO+H.sub.2 (Heterogeneous water gas shift reaction-endothermic)
C+CO.sub.2->2CO (Boudouard equilibrium-endothermic)
2C+->CO.sub.2
[0039] A raw synthesis gas product may be characterized by a dirty mixture of gases and solids, comprised of carbon monoxide, hydrogen, carbon dioxide, methane, ethylene, ethane, acetylene, and a mixture of unreacted carbon and ash, commonly called ‘char’, as well as elutriated bed material particulates, and other trace contaminants, including but not limited to ammonia, hydrogen chloride, hydrogen cyanide, hydrogen sulfide, carbonyl sulfide, and trace metals. Syngas may also contain a variety of volatile organic compounds (VOC) or aromatics including benzene, toluene, phenol, styrene, xylene, and cresol, as well as semi-volatile organic compounds (SVOC) or polyaromatics, such as indene, indan, napthalene, methylnapthalene, acenapthylene, acenapthalene, anthracene, phenanthrene, (methyl-) anthracenes/phenanthrenes, pyrene/fluoranthene, methylpyrenes/benzofluorenes, chrysene, benz[a] anthracene, methylchrysenes, methylbenz[a]anthracenes, perylene, ben-zo[a]pyrene, dibenz[a,kl] anthracene, and dibenz[a,h]anthracene.
[0040] There is a number of patents relating to different technologies for the synthesis gas cleaning including US 20110126460 A1 and WO 2015089554 A1. The present invention routes the dirty exhaust from the pyrolysis and gasifier 16 into a gas cleaning system 17. Blowers or fans, pumps or other equipment (not shown) can be added to ensure proper flow of the dirty exhaust is maintained. Dry scrubbers with sorbent injectors that introduce limestone or hydrated lime into the gas streams will be added to control any trace of sulfur and nitrogen oxides. Synthesis gas cleanup equipment will consist of packed bed wet scrubbers with sodium hydroxide solutions, absorber vessels, and filters. Small dry scrubbers and/or filters will be used for particulate matter control, while the packed bed scrubbers will be used to neutralize HCl. In addition to the packed bed wet scrubbers, an absorber vessel used for gas purification will be added in to control H2S and COS.
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REFERENCES
[0046] 1. U.S. Energy Information Administration. (2013, 25 Jul.). International energy outlook 2013: World energy demand and economic outlook, ww.eia.gov/forecasts/ieo/world.cfm [0047] 2. Canada-wide Approach for the Management of Wastewater Bio solids. Canadian Council of Ministers of the Environment, 2012 [0048] 3. Hedden, K., et al., “A New Concept for the Production of Liquid Hydrocarbons from Natural Gas in Remote Areas”, Oil Gas—European Magazine, March 1994, pp. 42-44. [0049] 4. Chris Higman and Maarten van der Burgt. Gasification, Second Edition, Elsevier (2008). [0050] 5. Beychok, M. R., Process and environmental technology for producing SNG and liquid fuels, U.S. EPA report EPA-660/2-75-011, May 1975 [0051] 6. Thanapal S S, Annamalai K, Sweeten J, Gordillo G, (2011), “Fixed bed gasification of dairy biomass with enriched air mixture”. Appl Energy, doi:10.1016/j.apenergy.2011.11.072 [0052] 7. High temperature electrolyte supported Ni-GDC/YSZ/LSM SOFC operation on two-stage Viking gasifier product gas, Ph. Hofmann et al. in Journal of Power Sources 173 (2007) 357-366 [0053] 8. Fundamental Issues in Control of Carbon Gasification Reactivity edited by L. Lahaye, Pierre Ehrburger Centre de Recherches sur la Physico-Chimie des Surfaces Solides—C.N.R.S., Mulhouse, France, 2012 [0054] 9. Encyclopedia of Electrochemical Power Sources edited by Chris K. Dyer, Patrick T. Moseley, Zempachi Ogumi, David A. J. Rand, Bruno Scrosati. Elsevier, 2009 [0055] 10. A. Mountouris, E. Voutsas, D. Tassios, 2006 Solid waste plasma gasification: Equilibrium model development and exergy analysis. Energy Conyers. Manage. 4717231737 [0056] 11. U.S. Environmental Protection Agency (2010 Municipal solid waste in the United States: 2009 Facts and Figures Washington, D.C. [0057] 12. A. S. An′shakov, V. A. Faleev, A. A. Danilenko, E. K. Urbakh, A. E. Urbakh, 2007 Investigation of plasma gasification of carbonaceous technogeneous wastes. Thermophys. Aeromech. 14607616
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