Abstract: A method for treatment of ash from incineration plants includes: collecting ash from an incinerator; feeding the collected ash and additional feed material to a gasification/vitrification reactor; vitrifying the ash and additional feed material in the gasification/vitrification reactor, to form a slag of molten material; allowing the slag to flow from the gasification/vitrification reactor and solidify outside the gasification/vitrification reactor; gasifying volatile components in the ash and the additional feed material; combusting syngas generated in the gasification/vitrification reactor in a secondary combustion zone in the gasification/vitrification reactor; and supplying products of the syngas combustion to the incinerator to augment the thermal environments of the incinerator. An apparatus used to practice the method is also provided.

Abstract: An apparatus includes a reactor vessel containing a carbonaceous bed and having means for establishing an elevated temperature within the carbonaceous bed; and the reactor vessel also having one or more feed material inlets above the carbonaceous bed for depositing process material from outside the vessel onto the carbonaceous bed, one or more gas exhaust ports above the bed for exit of gaseous products from the vessel, and one or more slag ports at the bottom of the carbonaceous bed for exit of molten and vitreous material from the vessel; wherein the carbonaceous bed comprises bricks that contain carbon and are of varied size and shape of which at least 25% of the total carbon content of the bed comprises spent pot liner material from aluminum processing, and wherein the bricks further comprise at least one of: Portland cement, potassium silicate cement, or aluminum silicate cement.

Abstract: A method for treatment of ash from incineration plants includes: collecting ash from an incinerator; feeding the collected ash to a vitrification reactor; vitrifying the ash in the vitrification reactor, to form a slag of molten material; allowing the slag to flow from the vitrification reactor and solidify outside the vitrification reactor; gasifying volatile components in the ash and the additional feed material; and routing flue gas generated in the vitrification reactor to a heat exchanger, wherein the heat exchanger is connected to a heat recovery steam generator that receives exhaust from the incinerator.

Abstract: A process for forming a carbonaceous article for use among particles in a carbonaceous bed of a thermal reactor, includes forming bricks having a material composition including carbon containing particles other than coke, and at least one of Portland cement, potassium silicate cement, and aluminum silicate cement, in an approximate weight % other than water of: 40 to 95 parts of the carbon containing particles, 0 to 20 parts of the Portland cement, 0 to 20 parts of the potassium silicate cement, and 0 to 20 parts of the aluminum silicate cement.

Abstract: A process for forming and maintaining a carbonaceous bed with coke replacement units suitable for use in pyrolytic processes includes the steps of: forming a plurality of non-coke units that are either or both irregularly shaped natural wood blocks and bricks including carbon-containing fines and one or more binders; forming an initial carbonaceous bed by a quantity of particles of coke in which at least about 25% of the carbon content of the initial bed is provided by said quantity of non-coke units and up to about 75% of the carbon content of the initial bed is provided by said quantity of particles of coke; and performing a pyrolytic process with the carbonaceous bed including reacting carbon in the bed with other added process material at an elevated temperature in the bed and supplementing carbon material during the pyrolytic process by adding additional carbon material of which at least 25% of the additional carbon material is not coke.

Abstract: An apparatus includes a reactor vessel containing a carbonaceous bed and having means for establishing an elevated temperature within the carbonaceous bed; and the reactor vessel also having one or more feed material inlets above the carbonaceous bed for depositing process material from outside the vessel onto the carbonaceous bed, one or more gas exhaust ports above the bed for exit of gaseous products from the vessel, and one or more slag ports at the bottom of the carbonaceous bed for exit of molten and vitreous material from the vessel; wherein the carbonaceous bed comprises bricks that contain carbon and are of varied size and shape of which at least 25% of the total carbon content of the bed comprises spent pot liner material from aluminum processing, and wherein the bricks further comprise at least one of: Portland cement, potassium silicate cement, or aluminum silicate cement.

Abstract: A method for treatment of ash from incineration plants includes: collecting ash from an incinerator; feeding the collected ash and additional feed material to a gasification/vitrification reactor; vitrifying the ash and additional feed material in the gasification/vitrification reactor, to form a slag of molten material; allowing the slag to flow from the gasification/vitrification reactor and solidify outside the gasification/vitrification reactor; gasifying volatile components in the ash and the additional feed material; combusting syngas generated in the gasification/vitrification reactor in a secondary combustion zone in the gasification/vitrification reactor; and supplying products of the syngas combustion to the incinerator to augment the thermal environments of the incinerator. An apparatus used to practice the method is also provided.

Abstract: A method for treatment of ash from incineration plants includes: collecting ash from an incinerator; feeding the collected ash to a vitrification reactor; vitrifying the ash in the vitrification reactor, to form a slag of molten material; allowing the slag to flow from the vitrification reactor and solidify outside the vitrification reactor; gasifying volatile components in the ash and the additional feed material; and routing flue gas generated in the vitrification reactor to a heat exchanger, wherein the heat exchanger is connected to a heat recovery steam generator that receives exhaust from the incinerator.