Abstract: A system and method of thermally processing carbonaceous materials, and especially sustainably cultivated woody biomass or cellulosic biomass sorted from municipal solid waste, to produce green fuel, such as diesel, sustainable aviation fuel and other beneficial by-products, including biochar. Synthesis gas is made by gasifying sustainably grown biomass, the thermal energy from which is used to create steam for treatment of biochar by-product to produce higher value activated carbon. Oxygen for the gasifier and hydrogen for a Fischer Tropsch (FT) or other catalytic synthesis stage of the process are generated by electrolysis of water using sustainably produced electricity. The gasification and electrolysis processes are operated to produce a 2:1 ratio of hydrogen to carbon monoxide needed for FT or other catalytic synthesis. The hydrocarbon product is distilled as required to produce either green alcohols or green diesel fuel and sustainable aviation fuel.

Abstract: A method for thermally converting plastics and biomass, and especially non-recyclable waste plastic and or biomass, to primarily liquid phase hydrocarbons is a three step process comprised of hydrothermal treatment, steam cracking and coking. Plastic or plastic and biomass feedstocks are reduced in particle size to inch minus or smaller and suspended in a liquid slurry. The slurry is pumped to high pressure and heated to a temperature high enough to initiate de-polymerization. The resulting partially de-polymerized slurry is sent to a multi-phase separation system via a pressure reduction valve and thereafter subjected to steam cracking to further reduce the average molecular weight of the hydrocarbon components. The resulting gas phase hydrocarbon mixture is quenched, and naphtha, middle distillate, and heavy oils are condensed out. The residual heavy oil phase is further reduced in pressure and sent to a coker from which additional liquid hydrocarbon product is recovered.

Abstract: A method for thermally converting plastics and biomass, and especially non-recyclable waste plastic and or biomass, to primarily liquid phase hydrocarbons is a three step process comprised of hydrothermal treatment, steam cracking and coking. Plastic or plastic and biomass feedstocks are reduced in particle size to inch minus or smaller and suspended in a liquid slurry. The slurry is pumped to high pressure and heated to a temperature high enough to initiate de-polymerization. The resulting partially de-polymerized slurry is sent to a multi-phase separation system via a pressure reduction valve and thereafter subjected to steam cracking to further reduce the average molecular weight of the hydrocarbon components. The resulting gas phase hydrocarbon mixture is quenched, and naphtha, middle distillate, and heavy oils are condensed out. The residual heavy oil phase is further reduced in pressure and sent to a coker from which additional liquid hydrocarbon product is recovered.

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 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.

Abstract: A multi-zone fluidized bed hydrocarbon conversion process and apparatus for producing gas and distillable liquid products from heavy hydrocarbon feedstocks. The feedstock is introduced into an upper fluidized bed primary cracking zone maintained at temperature of 850.degree.-1400.degree. F. for cracking reactions therein, and resulting tars and coke are deposited on and within a particulate carrier material contained therein. The carrier material containing said tars and coke descends successively through a stripping zone to remove tars and an interim controlled temperature zone for secondary cracking against an upflowing hot reducing gas, then descends into a lower fluidized bed gasification zone. The gasification zone is maintained at temperature of 1600.degree.-1900.degree. F. by oxygen-containing gas and steam introduced therein to gasify the coke deposits and produce the reducing gas.

Abstract: In the introduction of fresh carbonaceous particles into a fluid-bed reaction zone at injection velocities in excess of 20 ft/sec, a shroud gas is passed through a shroud passage on the injection nozzle at a velocity in excess of about 750 ft/sec, preferably at from about 1,000 to about 5,000 ft/sec, in sufficient quantities to supply a substantial portion of the overall energy input into the reaction zone for dispersion of the fresh particles and for breaking up of any agglomerates formed upon injection of the fresh particles into the reaction zone. By accommodating the agglomerating tendencies of the fresh feed material, the high energy shroud gas effectively contributes to the prevention of defluidization of the bed. The shroud gas may be inert or may comprise a gaseous reagent that reacts with the fresh carbonaceous particles in the reaction zone. The energy supplied by the shroud gas desirably is at least about 80% of said energy input to the reaction zone.

Abstract: Fresh carbonaceous particles are introduced into a fluid-bed reaction zone containing a bed of non-agglomerating particles at an injection velocity in excess of about 200 ft/sec with the fresh particles having been preheated to a temperature within the plastic transformation range of the particles and introduced rapidly and directly into said bed of non-agglomerating particles. The reaction zone may be a hydrocarbonization zone, a carbonization zone, a gasification zone or any other fluid-bed reaction zone in which defluidization may be caused by undue agglomeration of the feed particles. A fluidized stream of the preheated carbonaceous particles may be introduced at said high injection velocity in a vertically upwards direction or otherwise, as from one or more injection points positioned vertically along the side of the reaction zone.