Pyrolysis and combustion process and system

Claim 2

A process for pyrolysis and combustion of combustible solid material which comprises: introducing combustible solid feed material containing volatile matter into an upper section of a pyrolysis chamber having a lower section and a bottom, moving said material downwardly at a controlled rate through multiple stage zones in said pyrolysis chamber, said multiple stage zones being provided by a series of spaced vertically disposed horizontally moveable grates in said pyrolysis chamber, depositing carbon char in the lower section of the pyrolysis chamber, introducing air into the lower section of said pyrolysis chamber and partially oxidizing said char to form hot gaseous products, passing said hot gaseous products of the partial oxidation of said carbon char upwardly countercurrent to the movement of said solid material in said pyrolysis chamber, and driving off said volatile matter in said solid material in a multistage equilibrium process, wherein substantial reaction equilibrium is achieved in each of said stage zones in the pyrolysis chamber between the solid combustible feed material and said upwardly passing hot gaseous products, removing ash and other non-combustible material from the bottom of said chamber, removing a hot overhead fuel gas comprised of said volatile matter from the solid material and the hot gaseous products of the partial oxidation of the carbon char, passing said overhead fuel gas to a combustion chamber for combustion thereof with air, subjecting said overhead fuel gas to combustion in said combustion chamber, and applying the resulting hot combustion gases exiting the combustion chamber to a heat load.

Claim 3

The process of claim 1, including passing said combustible solid material through a feed-lock system prior to the introduction of said solid material into said pyrolysis chamber.

Claim 4

The process of claim 1, including controlling the temperature of the overhead gas by controlling the flow rate of air for the partial oxidation of said char.

Claim 5

The process of claim 1, including depositing an excess of said carbon char in the lower section of said pyrolysis chamber and introducing steam into said excess carbon char to carry out a water gas reaction, and forming CO 2 and H 2 .

Claim 6

The process of claim 1, wherein said combustible solid material contains one or more acid components, and including passing the overhead fuel gas containing said components to a zone containing a chemical adsorbent for the acid components, and recoving a clean hot fuel gas substantially free of said acid components, for passage to said combustion chamber.

Claim 7

The process of claim 5, wherein said combustible solid material is a combustible solid industrial waste comprising essentially a cellulosic material containing an acid component selected from the group consisting of S and Cl, which results in said overhead fuel gas comprising hydrocarbons, CO, H 2 , N 2 and said acid component.

Claim 8

The process of claim 1, wherein said combustible solid material is a combustible solid industrial waste comprises essentially of cellulosic material, which results in said fuel gas comprising hydrocarbons, CO, H 2 and N 2 .

Claim 9

The process of claim 7, wherein the hot overhead fuel gas has a temperature ranging from about 800° F. to about 1,000° F., and said hot combustion gases exiting the combustion chamber having a temperature ranging from about 1,600° F. to about 1,700° F.

Claim 10

The process of claim 1, including quenching the ash and other non-combustible material in the bottom of said pyrolysis chamber prior to removal thereof.

Claim 11

A process for pyrolysis and combustion of combustible solid material which comprises: introducing combustible solid feed material derived from industrail waster and comprises essentially of carbonaceous material including volatile hydrocarbons, through a feed-lock system, introducing said solid material exiting said feed-lock system into an upper section of a pyrolysis chamber having a lower section and a bottom, moving said solid material downwardly in a plurality of successive vertically disposed stages in said pyrolysis chamber at a controlled rate, said vertically disposed stages being provided by a series of horizontally moveable vertically spaced grates in said pyrolysis chamber, depositing carbon char in the lower section of the pyrolysis chamber, flowing air into the carbon char in the lower section of said pyrolysis chamber and partially oxidizing said char to form hot gases containing C, H 2 and N 2 , passing said hot gases upwardly countercurrent to the downward movement of said solid material in said pyrolysis chamber, driving off said volatile hydrocarbons from said solid carbonaceous material and pyrolyzing it to form said carbon char, in a multistage equilibrium process, the rate of downward movement of the combustible solid material in the pyrolysis chamber in relation to the upward flow of the hot gases being such as to achieve substantial reaction equilibrium in each of said stages in the pyrolysis chamber between the solid combustible feed material and said upwardly passing hot gaseous products, removing a mixture of said volatile hydrocarbons and said hot gases as an overhead hot fuel gas from the upper section of said pyrolysis chamber, the overhead hot fuel gas being maintained in a predetermined temperature range by controlling the flow rate of air into the carbon char, quenching ash and other non-combustible material resulting from the partial oxidation of said char and removing same from the bottom of said pyrolysis chamber, introducing said hot overhead fuel gas into a combustion zone for combustion therein with an excess of oxygen, subjectng said overhead fuel gas to combustion in said combustion zone, and passing the resulting hot combustion gases to a heat load.

Claim 12

A process for pyrolysis and combustion of combustible solid material which comprises: introducing combustible solid feed material derived from industrail waster and comprises essentially of carbonaceous material including volatile hydrocarbons, through a feed-lock system, introducing said solid material exiting said feed-lock system into an upper section of a pyrolysis chamber having a lower section and a bottom, moving said solid material downwardly in a plurality of successive vertically disposed stages in said pyrolysis chamber at a controlled rate, said vertically disposed stages being provided by a series of horizontally moveable vertically spaced grates in said pyrolysis chamber, depositing carbon char in the lower section of the pyrolysis chamber, flowing air into the carbon char in the lower section of said pyrolysis chamber and partially oxidizing said char to form hot gases containing C, H 2 and N 2 , passing said hot gases upwardly countercurrent to the downward movement of said solid material in said pyrolysis chamber, driving off said volatile hydrocarbons from said solid carbonaceous material and pyrolyzing it to form said carbon char, in a multistage equilibrium process, the rate of downward movement of the combustible solid material in the pyrolysis chamber in relation to the upward flow of the hot gases being such as to achieve substantial reaction equilibrium in each of said stages in the pyrolysis chamber between the solid combustible feed material and said upwardly passing hot gaseous products, removing a mixture of said volatile hydrocarbons and said hot gases as an overhead hot fuel gas from the upper section of said pyrolysis chamber, the overhead hot fuel gas being maintained in a predetermined temperature range by controlling the flow rate of air into the carbon char, quenching ash and other non-combustible material resulting from the partial oxidation of said char and removing same from the bottom of said pyrolysis chamber, introducing said hot overhead fuel gas into a combustion zone for combustion therein with an excess of oxygen, subjectng said overhead fuel gas to combustion in said combustion zone, and passing the resulting hot combustion gases to a heat load.

Claim 13

The process of claim 10, wherein the hot overhead fuel gas has a temperature ranging from about 800° F. to about 1,000° F.

Claim 14

The process of claim 10, said combustible solid material containing an acid component selected from the group consisting of S and Cl, which results in said overhead fuel gas comprising hydrocarbons, CO, H 2 , N 2 and said acid component, and including passing the overhead fuel gas containing said acid component to a zone containing a bed of chemical adsorbent, and recovering a clean hot fuel gas substantially free of said acid component, for passage to said combustion zone.

Claim 15

The process of claim 12, said chemical adsorbent being calcium carbonate.

Claim 16

The process of claim 10, including maintaining a slight negative pressure in the pyrolysis chamber to prevent leakage of noxious vapors therefrom.

Claim 17

The process of claim 10, including depositing an excess of said carbon char in the lower section of said pyrolysis chamber and introducing steam into said excess carbon char to carry out a water gas reaction, and forming CO and H 2 .

Claim 18

The process of claim 10, including selectively diverting the overhead fuel gas to storage.

Claim 19

A process for pyrolysis and combustion of combustible solid material which comprises: introducing combustible solid material containing volatile matter into an upper section of a pyrolysis chamber having a lower section and a bottom, moving said material at a controlled rate downwardly through multiple stage zones in said pyrolysis chamber, said multiple stage zones being provided by a series of spaced vertically disposed horizontally moveable grates in said pyrolysis chamber, depositing carbon char in the lower section of the pyrolysis chamber, introducing air into the lower section of said pyrolysis chamber and partially oxidizing said char to form hot gaseous products, passing said hot gaseous products of the partial oxidation of said carbon char upwardly countercurrent to the movement of said solid material in said pyrolysis chamber, and driving off said volatile matter in said solid material in a multistage equilibrium process, wherein substantial reaction equilibrium is achieved in each of said stage zones in the pyrolysis chamber between the solid combustible feed material and said upwardly passing hot gaseous products, removing ash and other non-combustible material from the bottom of said chamber, and removing a hot overhead fuel gas comprised of said volatile matter from the solid material and the hot gaseous products of the partial oxidation of the carbon char.

Claim 20

A process for pyrolysis and combustion of combustible solid material which comprises: introducing combustible solid material containing volatile matter into an upper section of a pyrolysis chamber having a lower section and a bottom, moving said material at a controlled rate downwardly through multiple stage zones in said pyrolysis chamber, said multiple stage zones being provided by a series of spaced vertically disposed horizontally moveable grates in said pyrolysis chamber, depositing carbon char in the lower section of the pyrolysis chamber, introducing air into the lower section of said pyrolysis chamber and partially oxidizing said char to form hot gaseous products, passing said hot gaseous products of the partial oxidation of said carbon char upwardly countercurrent to the movement of said solid material in said pyrolysis chamber, and driving off said volatile matter in said solid material in a multistage equilibrium process, wherein substantial reaction equilibrium is achieved in each of said stage zones in the pyrolysis chamber between the solid combustible feed material and said upwardly passing hot gaseous products, removing ash and other non-combustible material from the bottom of said chamber, and removing a hot overhead fuel gas comprised of said volatile matter from the solid material and the hot gaseous products of the partial oxidation of the carbon char.

Claim 23

The system of claim 18, wherein said means for introducing the solid feed material includes a feed-lock system for receiving the combustible solid material prior to introduction thereof into said pyrolysis chamber.

Claim 24

The system of claim 18, including a chemical adsorbent treatment zone, and means for introducing the overhead fuel gas from said pyrolysis chamber first into said chemical adsorbent treatment zone prior to introducing the overhead fuel gas into said combustion chamber.

Claim 25

The system of claim 18, including means for introducing steam into the lower section of said pyrolysis chamber to contact carbon in order to carry out a water gas reaction.

Claim 26

The system of claim 18, including means for quenching ash and other non-combustible material in the bottom of said pyrolysis chamber prior to removal thereof.

Claim 27

The system of claim 18, including means for maintaining a slight negative pressure in the pyrolysis chamber to prevent leakage of noxious vapors therein.

Claim 28

The system of claim 18, including means for selectively diverting overhead fuel gas away from the combustion chamber.