Fluidized bed reactor apparatus and related gasification system

Claim 2

A gasification reactor assembly comprised of the following: (a) a reactor vessel housing structure; (b) a fluidized bed reaction chamber having an inner periphery; (c) a means for generating a fluidized bed reaction atmosphere within said reaction chamber, wherein said means is comprised of a floating plenum chamber located proximate said reaction chamber and not fixed to the inner periphery of said reaction chamber, said plenum chamber being floatably seated on refractory material and unattached to any portion of the reactor vessel housing structure to allow for differential thermal expansion; (d) a means for introducing oxygen into said plenum chamber; (e) a means for introducing steam into said plenum chamber, said oxygen and steam being premixed within said plenum chamber; (f) a means for introducing combustible carbon containing material into said reaction chamber; and (g) a means for removing the resultant product gases from within said reaction chamber.

Claim 3

The combination of claim 1, wherein said floating plenum chamber is located near the bottom of said reactor housing and is provided with a perforated, conically-shaped plenum grid and associated ash removal means.

Claim 4

The combination according to claim 2, wherein said plenum grid slopes downwardly and inwardly to a central withdrawal pipe which is adapted to remove undesirable ash formed within the reaction chamber.

Claim 5

The combination according to claim 3, wherein said plenum chamber is comprised of a pair of conically-shaped plates which are integrally connected at their respective outer ends and which include downwardly extending wall members at their respective inner ends, wherein the upper plenum plate includes a plurality of openings and is separated from the lower plenum plate by suitable support means.

Claim 6

The combination according to claim 4, wherein said upper plate is separated from said lower plate by a plurality of equidistantly spaced bracket-like members.

Claim 7

The combination according to claim 5, wherein said perforated upper plate is provided with a plurality of nozzles extending therethrough.

Claim 8

The combination according to claim 6, wherein said nozzles extend therethrough at an angle perpendicular to the surface of said upper plate.

Claim 9

The combination according to claim 5, wherein said bracket-like members include apertures to facilitate the mixing of gases introduced into said plenum chamber.

Claim 10

The combination according to claim 4, wherein said downwardly extending wall members comprise first and second annular legs extending from the upper and lower plenum plates, respectively, said first leg having a smaller diameter than said second leg, and including first and second annular expansion means adapted to floatably receive said first and second legs, respectively, in a seating relationship.

Claim 11

The combination according to claim 9, wherein said plenum grid further includes an expansion means and an inlet pipe passing therethrough.

Claim 12

A gasification reactor assembly comprised of the following: (a) a reactor vessel housing structure; (b) a fluidized bed reaction chamber having an inner periphery; (c) a means for generating a fluidized bed reaction atmosphere within said reaction chamber, wherein said means is comprised of a floating plenum chamber located proximate said reaction chamber and not fixed to the inner periphery of said reaction chamber, said plenum chamber being floatably seated on refractory material and unattached to any portion of the reactor vessel housing structure to allow for differential thermal expansion; (d) a means for introducing oxygen into said plenum chamber; (e) a means for introducing steam into said plenum chamber, said oxygen and steam being premixed within said plenum chamber; (f) a means for introducing combustible carbon containing material feed into said reaction chamber; (g) a means for removing the resultant product gases from within said reaction chamber; and (h) a floating heat exchanger located within said reactor housing structure, wherein said heat exchanger comprises multiple vertical tubes and the exchanger is adapted to allow for differential thermal expansion within the reactor.

Claim 13

A gasification reactor assembly comprised of the following: (a) a reactor vessel housing structure; (b) a fluidized bed reaction chamber having an inner periphery; (c) a means for generating a fluidized bed reaction atmosphere within said reaction chamber, wherein said means is comprised of a floating plenum chamber located proximate said reaction chamber and not fixed to the inner periphery of said reaction chamber, said plenum chamber being floatably seated on refractory material and unattached to any portion of the reactor vessel housing structure to allow for differential thermal expansion; (d) a means for introducing oxygen into said plenum chamber; (e) a means for introducing steam into said plenum chamber, said oxygen and steam being premixed within said plenum chamber; (f) a means for introducing combustible carbon containing material feed into said reaction chamber; (g) a means for removing the resultant product gases from within said reaction chamber; and (h) a floating heat exchanger located within said reactor housing structure, wherein said heat exchanger comprises multiple vertical tubes and the exchanger is adapted to allow for differential thermal expansion within the reactor.

Claim 14

The combination according to claim 11, wherein said heat exchanger is located near an upper portion of said reactor housing structure, and is adapted for use with the internally developed high temperature product gases and an external source of lower temperature steam.

Claim 15

The combination according to claim 11, wherein said heat exchanger is comprised of a bayonet-type bundle heat exchanger containing a plurality of concentric tubes having downflowing gas in each inner tube and upflowing gas in the annulus between the concentric tubes.

Claim 16

The combination according to claim 12, wherein said heat exchanger includes an upper tubesheet and associated expansion means wherein said upper tubesheet is adapted to suspend from an upper portion of said reactor housing structure.

Claim 17

The combination according to claim 12, wherein said upper reactor housing structure includes a circumferentially extending shelf, and wherein said heat exchanger includes an upper tube sheet adapted to suspend from said shelf, whereby expansion means are provided proximate said shelf and tube sheet.

Claim 18

A gasification reactor assembly comprised of the following: (a) a reactor vessel housing structure; (b) a fluidized bed reaction chamber having an inner periphery; (c) a means for generating a fluidized bed reaction atmosphere within said reaction chamber, wherein said means is comprised of a floating plenum chamber located proximate said reaction chamber and not fixed to the inner periphery of said reaction chamber, said plenum chamber being floatably seated on refractory material and unattached to any portion of the reactor vessel housing structure to allow for differential thermal expansion; (d) a means for introducing oxygen into said plenum chamber; (e) a means for introducing steam into said plenum chamber, said oxygen and steam being premixed within said plenum chamber; (f) a means for introducing combustible carbon containing material feed into said reaction chamber through the upper portion of said reactor vessel; (g) a means for removing the resultant product gases and associated particulate matter from within said reaction chamber; (h) a floating heat exchanger located within said reactor housing structure, wherein said heat exchanger is adapted to allow for differential thermal expansion; and (i) a means for separating said gases from said associated particulate matter and for recycling said particulate matter to said reaction chamber.

Claim 19

A gasification reactor assembly comprised of the following: (a) a reactor vessel housing structure; (b) a fluidized bed reaction chamber having an inner periphery; (c) a means for generating a fluidized bed reaction atmosphere within said reaction chamber, wherein said means is comprised of a floating plenum chamber located proximate said reaction chamber and not fixed to the inner periphery of said reaction chamber, said plenum chamber being floatably seated on refractory material and unattached to any portion of the reactor vessel housing structure to allow for differential thermal expansion; (d) a means for introducing oxygen into said plenum chamber; (e) a means for introducing steam into said plenum chamber, said oxygen and steam being premixed within said plenum chamber; (f) a means for introducing combustible carbon containing material feed into said reaction chamber through the upper portion of said reactor vessel; (g) a means for removing the resultant product gases and associated particulate matter from within said reaction chamber; (h) a floating heat exchanger located within said reactor housing structure, wherein said heat exchanger is adapted to allow for differential thermal expansion; and (i) a means for separating said gases from said associated particulate matter and for recycling said particulate matter to said reaction chamber.

Claim 20

The combination according to claim 16, wherein said separating means is comprised of a cyclone separator.

Claim 21

The combination according to claim 17, wherein said separated particulate matter is recycled to said reaction chamber by way of said means for introducing said source of combustible carbon containing material feed into said reaction chamber.

Claim 22

A gasification reactor assembly comprised of the following: (a) a reactor vessel housing structure with associated insulation means located within; (b) a fluidized bed reaction chamber having an inner periphery; (c) a means for introducing combustible carbon containing material feed into said reaction chamber; (d) a means for generating a fluidized bed reaction atmosphere within said reaction chamber, wherein said means is comprised of a floating plenum chamber located proximate said reaction chamber and not fixed to the inner periphery of said reaction chamber, said plenum chamber being floatably seated on refractory material and unattached to any portion of the reactor vessel housing structure to allow for differential thermal expansion, wherein said floating plenun chamber is located below said reaction chamber and is further comprised of a pair of conically-shaped plates which are integrally connected at their respective outer ends and which include downwardly extending wall members at their respective inner ends, wherein the upper plate includes a plurality of openings and is separated from the lower plate by suitable support means, a perforated conically-shaped plenum grid, which grid slopes downwardly and inwardly to a central withdrawal pipe wherein said plenum grid is connected to said upper plenum plate and both the plenum plate and plenum grid are provided with a plurality of nozzles extending therethrough; (e) a means for introducing oxygen into said plenum chamber; (f) a means for introducing saturated steam into said plenum chamber, said oxygen and steam being premixed within said plenum chamber; (g) a floating bayonet bundle type heat exchanger located within said reactor housing structure, wherein said heat exchanger is located near an upper portion of said reactor housing structure and is adapted for use with the internally-developed high temperature product gases and an external source of lower temperature steam wherein said heat exchanger is further comprised of an upper tube sheet and associated inner tubes, a lower tube sheet and associated outer tubes wherein said upper tube sheet is adapted to suspend from a circumferentially extending shelf located within said upper reactor housing structure, and expansion means which are provided proximate said shelf and upper reactor housing structure; and (h) a cyclone separator for separating said product gases from said associated particulate matter and for recycling said particulate matter to said reaction chamber by way of said means for introducing said combustible carbon containing material feed into said reaction chamber.

Claim 23

A gasification reactor assembly comprised of the following: (a) a reactor vessel housing structure with associated insulation means located within; (b) a fluidized bed reaction chamber having an inner periphery; (c) a means for introducing combustible carbon containing material feed into said reaction chamber; (d) a means for generating a fluidized bed reaction atmosphere within said reaction chamber, wherein said means is comprised of a floating plenum chamber located proximate said reaction chamber and not fixed to the inner periphery of said reaction chamber, said plenum chamber being floatably seated on refractory material and unattached to any portion of the reactor vessel housing structure to allow for differential thermal expansion, wherein said floating plenun chamber is located below said reaction chamber and is further comprised of a pair of conically-shaped plates which are integrally connected at their respective outer ends and which include downwardly extending wall members at their respective inner ends, wherein the upper plate includes a plurality of openings and is separated from the lower plate by suitable support means, a perforated conically-shaped plenum grid, which grid slopes downwardly and inwardly to a central withdrawal pipe wherein said plenum grid is connected to said upper plenum plate and both the plenum plate and plenum grid are provided with a plurality of nozzles extending therethrough; (e) a means for introducing oxygen into said plenum chamber; (f) a means for introducing saturated steam into said plenum chamber, said oxygen and steam being premixed within said plenum chamber; (g) a floating bayonet bundle type heat exchanger located within said reactor housing structure, wherein said heat exchanger is located near an upper portion of said reactor housing structure and is adapted for use with the internally-developed high temperature product gases and an external source of lower temperature steam wherein said heat exchanger is further comprised of an upper tube sheet and associated inner tubes, a lower tube sheet and associated outer tubes wherein said upper tube sheet is adapted to suspend from a circumferentially extending shelf located within said upper reactor housing structure, and expansion means which are provided proximate said shelf and upper reactor housing structure; and (h) a cyclone separator for separating said product gases from said associated particulate matter and for recycling said particulate matter to said reaction chamber by way of said means for introducing said combustible carbon containing material feed into said reaction chamber.