Abstract: A method is provided for thermally processing waste to produce steam and generate energy while minimizing air pollutants in a staged thermal reactor. The method includes gasifying the waste to convert the waste to a fuel gas and a substantially carbon free, inert, granulated, sintered mineral ash and reforming the fuel gas auto-thermally to minimize creation of nitrogen oxide when the fuel gas is combusted. The method further includes burning the reformed fuel gas to minimize creation of nitrogen oxide in a flame region of a fuel gas burner and recirculating cooled flue gas to control oxygen content and temperature during the reforming operation and the burning operation. In one example, reforming the fuel gas converts non-molecular nitrogen species into molecular nitrogen in an auto-thermal non-catalytic reformer unit by decomposition reactions promoted by a prevailing reducing gas atmosphere.

Abstract: A method is provided for thermally converting non-radioactive combustible wastes to a substantially non-hazardous, non-leachable, sintered particulate carbon-less ash by-product in a kiln having a plurality of reaction zones. The kiln including first and second ends and a body provided between the first and second ends that defines a cavity having a refractory lining that provides resistance to heat conduction. A processor and flow rate controllers are provided that control a flow rate through the body of waste that enters at the first end of the kiln and the flow rate of oxidant gas that enters at the second end of the kiln, the second end being opposite to the first end. The body may be positioned substantially horizontal and may include a length-to-diameter ratio and a resistance to heat conduction that provides a temperature gradient within the cavity to forms separate reaction zones during operation.

Abstract: A method is provided for thermally processing waste to produce steam and generate energy while minimizing air pollutants in a staged thermal reactor. The method includes gasifying the waste to convert the waste to a fuel gas and a substantially carbon free, inert, granulated, sintered mineral ash and reforming the fuel gas auto-thermally to minimize creation of nitrogen oxide when the fuel gas is combusted. The method further includes burning the reformed fuel gas to minimize creation of nitrogen oxide in a flame region of a fuel gas burner and recirculating cooled flue gas to control oxygen content and temperature during the reforming operation and the burning operation. In one example, reforming the fuel gas converts non-molecular nitrogen species into molecular nitrogen in an auto-thermal non-catalytic reformer unit by decomposition reactions promoted by a prevailing reducing gas atmosphere.

Abstract: An apparatus is provided that receives waste and generates electrical power or thermal energy with minimal NOx emissions. A gasifier is provided that receives the waste and air to produce fuel gas for delivery to a fluidly coupled reformer. The reformer receives the fuel gas, recycled flue gas, and air to auto-thermally produce a reformed fuel gas and destroy fuel gas pollutants at a first temperature without a catalyst. A burner is fluidly coupled to the reformer and receives recycled flue gas and air to oxidize the reformed fuel gas at a second temperature that prevents nitrogen oxide formation, the second temperature being lower than the first temperature. A quench chamber is fluidly coupled to the burner and receives flue gas from the burner for quenching with recycled flue gas. A heat recovery system is fluidly coupled to the reformer, burner, and quench chamber to extract usable energy.

Abstract: A method is provided for thermally converting non-radioactive combustible wastes to a substantially non-hazardous, non-leachable, sintered particulate carbon-less ash by-product in a kiln having a plurality of reaction zones. The kiln including first and second ends and a body provided between the first and second ends that defines a cavity having a refractory lining that provides resistance to heat conduction. A processor and flow rate controllers are provided that control a flow rate through the body of waste that enters at the first end of the kiln and the flow rate of oxidant gas that enters at the second end of the kiln, the second end being opposite to the first end. The body may be positioned substantially horizontal and may include a length-to-diameter ratio and a resistance to heat conduction that provides a temperature gradient within the cavity to forms separate reaction zones during operation.

Abstract: An apparatus is provided that receives waste and generates electrical power or thermal energy with minimal NOx emissions. A gasifier is provided that receives the waste and air to produce fuel gas for delivery to a fluidly coupled reformer. The reformer receives the fuel gas, recycled flue gas, and air to auto-thermally produce a reformed fuel gas and destroy fuel gas pollutants at a first temperature without a catalyst. A burner is fluidly coupled to the reformer and receives recycled flue gas and air to oxidize the reformed fuel gas at a second temperature that prevents nitrogen oxide formation, the second temperature being lower than the first temperature. A quench chamber is fluidly coupled to the burner and receives flue gas from the burner for quenching with recycled flue gas. A heat recovery system is fluidly coupled to the reformer, burner, and quench chamber to extract usable energy.

Abstract: The invention provides an apparatus that thermally processes solid waste such as municipal solid waste to generate heat for production of steam that is employed to generate electrical power. The apparatus provides clean efficient gasification of refuse derived fuel to minimize air pollutants such as nitrogen oxides and uses released thermal energy to produce steam for electricity. Carbon in the solid waste is converted to synthesis gas or syngas that is combusted to generate steam or electricity. The apparatus recovers energy from residual carbon that is normally rejected by air fed gasifiers and partially recycles the flue gas to control combustion temperature and oxygen content in the fuel gas burner. The apparatus extends boiler service life by reducing the temperature of hot gases entering the boiler and produces clean electrical energy from materials that otherwise would be discarded as environmentally damaging waste.

Abstract: A method is provided of thermally processing carbonaceous ash and ancillary carbonaceous material to produce a carbon-free inert, pozzolanic, or cementitious material and synthesis gas. The carbonaceous ash and ancillary fuels are fed into a thermal reactor along with oxides provided in the ash or in additives including limestone or glass. Carbon in the ancillary fuel and coal fly ash is converted to synthesis gas that is combusted to generate process steam and electricity. Remaining ash exits the thermal reactor chamber for processing at high temperature in a kiln gasifier to react the remaining fixed carbon and produce carbon-free partially-fused nodules or clinker that are cooled and ground to a desired fineness for cementitious or aggregate material in concrete. Carbonaceous ash, especially high carbon coal fly ash and other carbonaceous waste, are converted to energy and non-toxic, carbon-free aggregate or cementitious material used as architectural fill or in concrete mixes.

Abstract: The invention provides a system and method of thermally processing high carbon coal fly ash to produce hydraulically reactive or pozzolanic supplemental cementitious material (SCM) and synthesis gas. In this “ash to energy and cement” (ATEC) process, coal fly ash and ancillary fuels are fed into a thermal reactor along with oxide materials, such as limestone. Carbon in the ancillary fuel and in the coal fly ash is converted to synthesis gas that is combusted to generate steam or electricity. The remaining low-carbon ash and bed material exits the thermal reactor chamber and is further processed at high temperature in a kiln or slagging unit to produce partially fused nodules or clinker. The nodules or clinker are cooled and ground to a desired fineness for use as a cementitious materials. The ATEC process effectively converts high carbon coal fly ash waste to energy and value added SCM.

Abstract: The invention provides a system and method for the efficient, clean and simultaneous conversion of multiple fuels, including but not limited to waste derived gas, liquid and solid phase fuels, to electrical energy. The present invention used a closely coupled combined thermal cycle system based on an air fed gasifier and an internal combustion engine. Steam generated by exhaust heat from an internal combustion engine and from the combustion of syngas produced by the gasifier is used to power an admission steam turbine in an efficient system in which components such as water treatment, heat recovery, and other components are common to gasifier and the internal combustion engine. The invention offers several advantages over other combined cycle power plants employing gasifiers.