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US 12,534,673 B2Granted
Pyrolysis systems, methods, and resultants derived there from
OwnerRichard D Tuckerinventor
Life of this patent
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Abstract
A system and process for the resultant gas constituent-controlled gasification of a carbonaceous feedstock uses feedback loop-controlled pyrolysis to produce a stable and predictable gas product from a variable or unknown feedstock, such as MSW, that may include methane, ethane, and other desirable hydrocarbon gases, and a solid product, that includes activated Carbon or Carbon.
Claims20
A pyrolysis system for the controlled gasification of a carbonaceous feedstock, comprising:
- a multi-zone pyrolysis unit comprising a plurality of independently temperature-controlled chambers, each configured to operate within an optimized thermal range for staged pyrolysis, and wherein the multi-zone pyrolysis unit includes adjustable chamber walls configured to dynamically alter the length of the heating chambers to match the specific heat profile of different feedstocks;
- a counter-rotating auger-retort mechanism within the multi-zone pyrolysis unit, wherein the auger and retort are configured to rotate in opposite directions to enhance uniform feedstock heating and reaction efficiency;
- at least one waste heat injector positioned to generate a swirling heat flow around the feedstock, promoting uniform energy distribution;
- a real-time process monitoring system, including spectral analysis sensors, configured to dynamically adjust pyrolysis parameters based on gas composition feedback;
- a hydrogen production sub-system fluidly connected to the pyrolysis unit, the sub-system comprising an incomplete combustion retort configured to receive a portion of the solid product from the pyrolysis unit and, through controlled low-oxygen injection, produce carbon monoxide, and a water gas shift reactor configured to react the carbon monoxide with steam to produce hydrogen;
- and
- a smart-grid-enabled control system, utilizing a layered communication protocol stack, configured for Internet Protocol (IP)-based process monitoring and optimization of both the pyrolysis unit and the hydrogen production sub-system.
4 more elements
A system for the controlled gasification of a carbonaceous feedstock, comprising:
- a multi-zone pyrolysis unit comprising a plurality of independently temperature-controlled chambers with adjustable chamber walls configured to be dynamically altered to match the specific heat profile of the feedstock;
- a counter-rotating auger-retort mechanism within the multi-zone pyrolysis unit configured to pyrolyze the feedstock and produce a gas product and a solid product;
- a real-time process monitoring system with spectral analysis sensors configured to monitor the gas product;
- a control system communicatively coupled to the spectral analysis sensors and the temperature-controlled chambers, configured to dynamically adjust the temperature of the chambers based on real-time feedback from the sensors;
- an incomplete combustion retort configured to receive a portion of the solid product from the pyrolysis unit and produce carbon monoxide via controlled low-oxygen injection;
- a water gas shift reactor configured to receive the carbon monoxide and react it with steam to produce hydrogen;
- and
- a smart-grid-enabled control system with an Internet Protocol (IP)-based interface configured to monitor and optimize the pyrolysis unit and the hydrogen production components.
5 more elements
A pyrolysis system for the controlled gasification of a carbonaceous feedstock, comprising:
- a multi-zone pyrolysis unit comprising a plurality of independently temperature-controlled chambers, each configured to operate within an optimized thermal range for staged pyrolysis, and wherein the multi-zone pyrolysis unit includes adjustable chamber walls configured to dynamically alter the length of the heating chambers to match the specific heat profile of different feedstocks;
- a counter-rotating auger-retort mechanism within the multi-zone pyrolysis unit, wherein the auger and retort are configured to rotate in opposite directions to enhance uniform heating and reaction efficiency;
- at least one waste heat injector positioned to generate a swirling heat flow around the feedstock, promoting uniform energy distribution;
- a real-time process monitoring system, including spectral analysis sensors, configured to dynamically adjust pyrolysis parameters based on gas composition feedback;
- a hydrogen production sub-system fluidly connected to the pyrolysis unit, the sub-system comprising an incomplete combustion retort configured to receive a portion of the solid product from the pyrolysis unit and, through controlled low-oxygen injection, produce carbon monoxide, and a water gas shift reactor configured to react the carbon monoxide with steam to produce hydrogen;
- and
- a smart-grid-enabled control system, utilizing a layered communication protocol stack, configured for Internet Protocol (IP)-based process monitoring and optimization of both the pyrolysis unit and the hydrogen production sub-system.
4 more elements
Dependencies are inferred from the claim text.