System and processes for upgrading synthetic gas produced from waste materials, municipal solid waste or biomass

A system for producing synthetic gas from solid fuel comprising waste material, municipal solid waste or biomass, and for upgrading the synthetic gas produced, the system comprising:

• a first thermal chamber having a gasification zone in which fuel is gasified by thermal oxidation to produce a first synthetic gas stream and heat;
• a pyrolysis reactor housed within the first thermal chamber;
• a fuel feed system that delivers a fuel stream into the pyrolysis reactor and the gasification zone in a manner that prevents oxygen from entering the pyrolysis reactor, wherein the heat produced in the gasification zone is imparted to the fuel stream in the pyrolysis reactor to cause pyrolysis of the fuel stream and produce a second synthetic gas stream;
• and
• a thermal catalytic reactor comprising a second thermal chamber and a catalyst chamber defined by a housing located within the second thermal chamber, the catalyst chamber having a selected catalyst therein, the second thermal chamber being operable to receive the first synthetic gas stream and completely thermally oxidize the first synthetic gas stream to produce high temperature flue gas that imparts heat to the housing of the catalyst chamber, and the catalyst chamber being operable to receive the second synthetic gas stream and to thermally crack the second synthetic gas stream to produce a cracked synthetic gas stream, and then to direct the cracked synthetic gas stream to the selected catalyst to yield a finished gas or liquid product having a desired chemical composition as determined by the selected catalyst in the catalyst chamber.

A process for producing synthetic gas from solid fuel comprising waste material, municipal solid waste or biomass, and for upgrading the synthetic gas produced, the process comprising the steps of:

• a. providing a first thermal chamber having a gasification zone and feeding a first fuel stream into the gasification zone;
• b. gasifying the first fuel stream by thermal oxidation in the gasification zone to produce a first synthetic gas stream and heat;
• c. providing a pyrolysis reactor housed within the first thermal chamber;
• d. feeding a second fuel stream into the pyrolysis reactor in a manner that prevents oxygen from entering the pyrolysis reactor, and pyrolyzing the second fuel stream using the heat produced in the gasification zone to produce a second synthetic gas stream;
• and
• e. providing a thermal catalytic reactor comprising a second thermal chamber and a catalyst chamber defined by a housing located within the second thermal chamber, the catalyst chamber having a selected catalyst therein;
• f. flowing the first synthetic gas stream into the second thermal chamber and completely thermally oxidizing the first synthetic gas stream to produce high temperature flue gas that imparts heat to the housing of the catalyst chamber;
• g. flowing the second synthetic gas stream through the catalyst chamber and thermally cracking the second synthetic gas stream to produce a cracked synthetic gas stream;
• and
• h. flowing the cracked synthetic gas stream through the selected catalyst to yield a finished gas or liquid product having a desired chemical composition as determined by the selected catalyst in the catalyst chamber.