Title of Invention

"A CONTINUOUS REACTOR FOR GLASIFICATION OR LOW TEMPERATURE CONVERSION OF ORGANIC MATERIAL"

Abstract A continuous reactor for (i) gasification or (ii) low temperature conversion for producing solid and gaseous fuels from organic starting materials involving agitator means (3) selectively disposed preferably substantially horizontally to separate an upper (1) and lower chambers (2) of the reactor and adapted to support the feed in the upper chamber (1) and also agitate the feed and favour processing for effective partial combustion/gasification and incorporating provisions for air supply (7) into said reactor, if required. The said upper chamber (1) adapted for feeding in the organic material (4) to be treated and for egress of the gaseous fuel generated and said lower chamber (2) at its lower end is provided with closable openings adapted to carry out at least anyone of (i) open for discharge of the solid fuel/coal or ash as and when generated and (ii) allow entry of air into the bottom of the lower chamber as and when required. The reactor system is simple to operate and use and thereby meet the much required need in the art for such a dual purpose user-friendly reactors for conversion of organic materials.
Full Text FIELD OF THE INVENTION
The present invention relates to reactors for gasification / low temperature conversion (LTC) of organic material for producing solid and gaseous fuel there from and, in particular, to a dual use continuous reactor for carrying out gasification as well as low temperature conversion to generate solid and gaseous fuel from organic material. The reactor can thus be selectively and advantageously used for generating producer gas for ready utilization as a process heat or for the power generation or alternatively the reactor can be used for internally heating organic material for gasification and convert the residue to coal, gas and oil in absence of air (anaerobically) at low temperature to achieve the desired low temperature conversion (LTC). The dual use reactor is cost effective to obtain and maintain and on the other hand is very simple and user friendly to carry out the desired gasification or the low temperature conversion.
BACKGROUND ART
It is well known that handling of organic matter is difficult and accumulation of waste by- product in refining or processing of organic matter is a problem. The cost of disposing such biomass is, therefore, high and is also suspect to the environmentally hazards. The art of land filling or open incinerator burning of organic waste is found harmful for environmental reasons and offends the present day laws and regulation directed to protecting the environment.
The above has lead to the development of systems, procedures and equipments whereby it would be possible to clean bum organic waste material to convert organic waste material into gas as an alternative energy source. US 5,666,890 discloses such a system directed to clean bum organic waste material.
Many known gasification systems involve the requirement of drying the biomass in order to reduce water content whereby it is possible to process waste even with high range of moisture content. Alternatively, it is also proposed to initially convert the biomass into pellets and chips before subjecting the same to combustion. Other system such as US 5,666,890 suggest basic pre- processing
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of the biomass through particle size reduction to facilitate the conversion process.
While the above systems and processes do appear to address the issue of effective processing of waste controlling environmental hazards, such process and devices are found to be expensive complex and sometime impracticable for the desired efficient disposal of waste.
Various other gasification systems have been also developed over the years to meet requirements such as for individual mills or plantation operation. Some of the system are also directed to efficient discharge of the gasses involving fan or blower. Likewise systems directed to efficient utilization of producer gas such as for use in diesel and petrol engines are also disclosed and made available to the art.
US Patent Application 20020046686 Al discloses a method and portable apparatus for the conversion of cellulose and other biomass waste materials through a pyrolysis and partial combustion sequence in a downdraft gasifler to produce a gas which can be immediately utilized to fuel an internal combustion engine in generator set (genset). More specifically, the heat from the combustion of part of the cellulose or other waste input is used to pyrolyze the remainder of the input to produce a mixture of permanent fuel gases.
US 6,790,383 teaches a method of gasifying organic materials (carbonaceous compounds) such as coal, shredded waste tire or waste oil into gaseous fuel, carbon monoxide and hydrogen and an apparatus therefore are provided. The method comprises the steps of supplying the organic materials into the reactor and reacting them with the water and carbon dioxide to produce carbon monoxide and hydrogen gas, discharging the carbon monoxide and hydrogen gas from the reactor, recycling a part of the carbon monoxide and hydrogen gas discharged from the reactor into the reactor, and reacting the carbon monoxide and hydrogen gas supplied into the reactor with oxygen to produce water and carbon dioxide. The method states of facilitating the control of temperature in the gasification reactor as well as producing fuel gas of high quality by increasing the concentration of hydrogen.
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US Patent Application 20040206280A1 discusses yet another method of treatment of domestic waste. A reaction space is provided, into which the waste to be treated is fed at a controlled rate. The waste is concurrently compacted to form a stopper preventing leakage of gases from the reaction space. An oxygen-containing gas is fed to the reaction space, in order to affect the combustion of the waste and produce gases and solid material. The gas is filtered through the solid material, causing the gases to react with the solid material, whereby to produce fuel gases and ash.
Also in our co pending Indian application no. 230/KOL/2004A there is disclosed a system for continuous conversion of organic starting materials to generate solid, liquid and gaseous fuels involving a lower reactor unit and an upper reactor unit operatively connected and adapted such that the organic material fed from the top is first pre- heated in the upper reactor unit by hot gases of the burnt fuel used in heating the lower reactor unit and finally converted into selective solid, liquid or gaseous fuel by further heating in the lower reactor unit; the inlets means being adapted to prevent entry of outside air into the reactor units and favour gravity feed for said conversion treatment with the outlet means for solid fuel generated at the bottom of said lower reactor unit comprising a converging shaped outlet . The system is directed to be energy efficient apart from being compact, easily portable and assembled at site and thus user friendly.
It would be apparent from the above that while several varieties of gasification and low temperature conversion systems producing gaseous fuel are made available to the art usually such system are either limited for use as a gasifier or the same is developed specifically for low temperature conversion of organic waste. Moreover, it is found that such devices are also sometimes either too complex and cost extensive to procure or suffer from lack of safety considerations. In some such known gasification equipments the partial pyrolysis of cellulose or other hydrocarbon material results in the formation of breakdown product which are gaseous at the elevated temperature in or near the gasification zone but which condense in pipes, valves and chambers at lower temperatures. Such complexities are very common for gasification equipment, which operated, in an up draft mode that is where the product gasses are removed from top of the vessel.
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Importantly, due to such known limitations of conventional gasifiers and low temperature conversion units there has been a continues need in the art to develop new and user friendly varieties of such gasifiers which could serve wide variety of conversions for ready application and use. However, the process of treatment of waste for gasification and for the solid fuel generation involving low temperature conversion being based on different approach for waste conversion, it has been difficult to provide for a device which could be effectively used for gasification as well as low temperature conversion for generation of solid and gaseous fuel.
OBJECTS OF THE INVETION
It is thus the basic object of the present invention to provide for a continuous reactor system which would we adapted for carrying out both gasification to generate producer gas and also for tow temperature conversion of organic material into solid and / or gaseous fuel and thereby meet the much required need in the art for such a dual purpose user-friendly reactors.
Another object of the present invention is to provide a dual use reactor for gasification and for low temperature conversion (LTC) for producing solid and gaseous fuel from organic starting material whereby on one hand the reactor would be adapted such that organic starting material can be combusted partially substoicio metrical amount of air to form producer gas and on the other hand also adapted to the carry out low temperature conversion by internally heating organic material leading to gasification and converting the residue to coal, gas and oil in absence of air (an aerobically) at low temperature efficiently and cost effectively.
It another object of the present invention is to provide a dual use reactor for gasification and / or low temperature conversion (LTC) for producing solid and gaseous fuel from organic starting material which would enable effective working on the organic material in the reactor to favour its combustion and processing for the purpose of gasification and / or the low temperature conversion without the complexity of sensors and / or mechanical drives.
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Yet another object of the present invention is directed to a dual use reactor for gasification and / or low temperature conversion of organic starting material which would have high throughput, need no external heating and can be operable under atmospheric pressure.
Yet further object of the present invention is directed to dual use reactor for gasification and / or low temperature conversion of organic starting material which would be simple and cost effective to obtain and use and importantly enable processing of waste material having a moisture content even up to 35% .
Another object of the present invention is to develop a simple and user friendly reactor system for carrying out gasification and low temperature conversion of organic starting material comprising of an upper and lower chamber wherein the lower chamber is adapted for the said dual use for gasification as well as the solid organic material conversion while the upper chamber is adapted to facilitate egress of the gasses emanating from the partial combustion/gasification of the organic material.
Yet further object of the present invention is directed to provide for user friendly dual purpose reactor for gasification and / or low temperature conversion of organic starting material which would also enable advantageous and desired processing of unshredded material by way of simple manual and / or automotive mechanism to favour cost effective and efficient conversion of organic material into gaseous or solid fuel.
Yet further object of the present invention is directed to a simple and user friendly dual use reactor system for gasification and / or solid fuel generation of organic material which can be carried out at relatively low temperature were the temperature of the upper chamber does not exceed 800°C while lower chamber temperature is kept below 1000°C on gasification and 500°C in case of low temperature conversion to generate solid fuel.
Yet further object of the present invention is directed to a simple and user friendly dual use reactor system for gasification and / or solid fuel generation from organic material which would be effective for carrying out low temperature conversion and thereby can be obtained of simple and cost effective material
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making its manufacture simple and the reactor readily available for wide scale use and application for conversion of organic material.
Yet further object of the present invention is directed to a reactor adapted for gasification or solid fuel generation from organic material incorporating simple and cost effective means for supporting the organic material for the purpose of conversion and its processing in the reactor for fast and efficient conversion of the biomass.
Yet another object of the present invention is to provide for a simple and user friendly reactor system for gasification or low temperature conversion to gaseous and solid fuel of organic material involving simple and user friendly mechanism for supporting the organic material in the reactor and controlling its processing as well as the gas control / flow through the reactor thereby providing for the much desired efficient conversion of the organic material.
SUMMARY OF THE INVENTION
Thus according to the basic aspect of the present invention there is provided a continuous reactor for gasification or low temperature conversion for producing solid and gaseous fuels from organic starting materials comprising :
reactor unit comprising a lower chamber and an upper chamber disposed one above the other;
agitator means selectively disposed preferably substantially horizontally to separate said upper and lower chambers and adapted to support the feed in the upper chamber and also agitate the feed and favour processing for effective partial combustion/gasification and incorporating provisions for air supply into said reactor, if required;
said upper chamber having means adapted for feeding in the organic material to be treated and for egress of the gaseous fuel generated upon partial combustion/gasification of the organic material;
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said lower chamber at its lower end is provided with closable openings adapted to carry out atleast anyone of (i) open for discharge of the solid fuel/coal or ash as and when generated and (ii) allow entry of air into the bottom of the lower chamber as and when required.
In the above disclosed continuous reactor the said agitator means is preferably selected from rods, pipes, tubular members, grates and comprise holes/slits for supply of air from outside to the region adjacent the bottom of the upper chamber preferably extending into the middle portion of bottom of the upper chamber. The said agitator means/rods are adapted and selectively disposed to process unshredded material, the heap of material supported by said agitator means/ rods provided to controll the gas flow and therefore the reaction speed.
It is thus possible by way of above disclosed dual use reactor for gasification and low temperature conversion (LTC) producing solid and gaseous fuel from organic starting material to on one hand achieve partial combustion with a sub stoichiometrical amount of air to form producer gas useful for process heat or power generation and on the other hand serve by internally heating the organic material leading to gasification and converting residue to coal, gas and oil in the absence of air (anaerobically) at low temperature.
In accordance with another aspect of the present invention there is provided a continuous reactor for gasification or low temperature conversion for producing solid and gaseous fuels from organic starting materials comprising :
reactor unit comprising a lower chamber and an upper chamber disposed one above the other;
agitator means comprising selectively disposed preferably substantially horizontally placed agitator/rod means to separate said upper and lower chambers and adapted to support the feed in the upper chamber and also agitate the feed and favour processing for effective partial combustion/gasification and incorporating provisions for air supply into said reactor, if required, and additional agitator/rod means in the upper chamber preferably angled up to 30 degrees from the horizontal and above said horizontally disposed agitator means.
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said upper chamber having means adapted for feeding in the organic material to be treated and for egress of the gaseous fuel generated upon partial combustion/gasification of the organic material;
said lower chamber at its lower end is provided with closable openings adapted to carry out atleast anyone of (i) open for discharge of the solid fuel/coal or ash as and when generated and (ii) allow entry of air into the bottom of the lower chamber as and when required.
Importantly and advantageously, in the reactor system of the invention the reactor is divided into the upper chamber and a lower chamber by means of the subatantially horizontally disposed agitator means which are adapted to support the heap of organic material for the purpose of conversion in a manner such as to control gas flow and therefore also the reaction speed for conversion. The agitator means can be preferably in the form of rods, pipes or in the form of grate and is preferably further adapted to enable processing unshreeded material found in the organic feed. The agitator means can be operated from outside the reactor manually and / or through automatised operation by operative connection through mechanical drive. The said agitator means/rods are further adapted and selectively disposed to process unshredded material, the heap of material supported by said agitator means/ rods provided to contrail the gas flow and therefore the reaction speed. Preferably, slits are provided for holding and rattling the agitator means/rods from outside manualy and/or by automatised means. The disposition of the agitator/rods ,spaces therebetween ,its dimensions and nos. are baseds upon the feed and the process to be carried out gasification or LTC.
In accordance with another aspect of the invention the said agitator means can be in the form of grate means preferably adapted and fixed on a vertical axis, the outer end of the grate means adapted to optionally rest on a support, the axis being supported by rods to the wall of the reactor and/ or the legs at the bottom of the reactor and optionally said vertical axis is operatively connected to a lever or a chain wheel or any other suitable drive for moving the axis back and forth or rotating the axis, preferably rattling.
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Preferably, for gasification the grate in the bottom of the lower chamber comprise of a fixed grate with small distance rods, which are intersected by more wide sectors, above the fixed grate there is a wide grate, which is movable, the intersections of the lower grate is superseded by rods of the upper grate such that large pieces of ash or inorganic material can pass through the grate on rattling or rotating the upper grate.
Advantageously, the said agitating means can be adapted to be activated manually and/or mechanically preferably comprising devices selected from pistons, chainwheel attached to an axis with grates and rods or any other suitable device.
The reactor system of the invention therefore while meeting the much required characteristic / features for such gasification and / or solid state conversion is provided as a compact and user friendly system requiring less machinery / control / drives and is therefore also cost effective to obtain.
In said continuous reactor system the means for feeding organic material in the upper chamber comprise inlets adapted for feeding preferably through hoppers with or without sealing means, said feed in the upper chamber preheated and partly gasified by the hot gases coming from below. Also, outlet means for the combustible gas formed in the process for further processing is provided in said upper chamber.
Importantly, for gasification the bottom openings of the lower chamber are adapted to allow air passsage therefrom into the reactor and also for ash disposal outlet. The partly decomposed material is burned in the lower chamber and the burning gases react with the material at the lower end of the upper chamber to form a producer gas. Also, for gasification the feed opening means in the upper chamber cooperate with hoppers at the top whereby the material blocks gases from flowing in and out of the reactor by forming a plug in the converging hopper.
For LTC operation , the lower chamber openings are adapted to be maintained air tight such as to maintain anaerobic conditions, the partly decomposed material forms coal and combustible gas, the produced gas removes the air, which initially is present, said agitator means adapted to pass air into the reactor at the lower end of the upper chamber whereby the produced gas is partly
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burned with air. Also; for LTC operation the coal bed in the lower-chamber are adapted to prevent air entering into the reactor from below during discharging, For LTC the top inlet means of the upper chamber can be adapted to be open, the material is fed from above and the produced gases are burned directly or in the alternative the feed in can be carried out using hopper means which is preferred.
Advantageously, the continuous reactor system of the invention is adapted to operate at relative low temperatures preferably the temperature in the upper chamber is upto 800°C and in the lower chamber the temperature is upto 1000°C on gasification and below 500°C on LTC.
The producer gas emanating at the top of the upper chamber is burned directly for process heat or cooled, purified and used for power generation preferably in an internal combustion engine or gas turbine.
According to another aspect of the present invention there is provided a continuous reactor system for gasification of organic starting materials comprising
a reactor unit comprising a lower chamber and an upper chamber disposed one above the other ;
the upper and lower chambers separated by agitation means preferably a set of rods/grate members, said agitation/rod means adapted and disposed to facilitate the required agitation and flow of the feed under
gravity;
said upper chamber having a feed inlet for the organic material to be treated and adapted such that the feed inlet can be kept closed by the organic material fed into the reactor upper chamber and outlet means for the gaseous fuel generated upon partial combustion/gasification of the organic material;
said lower chamber at its lower end is provided with openings adapted to allow entry of air into the bottom of the lower chamber for gasification and also discharge of ash as and where
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In accordance with yet further aspect of the present invention there is provided a continuous reactor system for low temperature conversion for producing solid and gaseous fuels from organic starting materials comprising :
a reactor unit comprising a lower chamber and an upper chamber disposed one above the other ;
the upper and lower chambers separated by agitator means preferably a set of rods/grate members with provisions for air supply into the reactor, for said conversion, said agitator means adapted and disposed to facilitate the required agitation and flow of the feed under gravity;
means in said upper chamber to feed the organic material to be treated and egress the gaseous fuel generated upon partial combustion/gasification of the organic material;
said lower chamber at its lower end is provided with closable openings adapted to carry out atleast anyone of (i) open for discharge of the solid fuel/coal as and when generated and (ii) allow entry of air into the bottom of the lower chamber.
As per the further aspect of the present invention there is provided a simple and cost-effective but highly efficient manner of gasification or low temperature conversion of organic comprising selectively adapting the continuous reactor of the invention disclosed above and carrying out the process for gasification or LTC.
It is thus possible by way of above disclosed dual use reactor for gasification and low temperature conversion (LTC) producing solid and gaseous fuel from organic starting material wherein on one hand it is possible to achieve partial combustion with a sub stoichiometrical amount of air to form producer gas useful for process heat or power generation and on the other hand can also serve by internally heating the organic material leading to gasification and converting residue to coal, gas and oil in the absence of air (anaerobically) at low temperature.
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Importantly and adventurously, in the reactor system of the invention the reactor is divided into the upper chamber and a lower chamber by means of agitator means which are adapted to support the heap of organic material for the purpose of conversion in a manner to control gas flow and therefore, also the reaction speed for conversion. The agitator means which can be in the form of rods, pipes or in the form of grate is further adapted to enable processing unshredded material found in the organic feed. The agitator means can be operated from outside the reactor manually and / or through automatised operation by operative connection through mechanical drive. The reactor therefore, white meeting the much require characteristic / features for such gasification and / or solid state conversion is provided as a compact and user friendly system requiring less machinery / control / drives and is therefore also cost effective to obtain and simple to use.
BRIEF DESCRIPTION OF THE ACCOMPNYING FIGURES
The details of the invention its object and advantageous are explained hereunder in grater detail in relation to non-limiting exemplary illustrations of the dual purpose continuous reactor adapted for gasification or low temperature conversion for producing solid and gaseous fuel from organic starting material of the invention wherein :
Figure 1A is front sectional view of the dual purpose reactor of the invention adapted for gasification or LTC of the organic material;
Figure 1B is a side sectional view of dual purpose reactor adapted for gasification or LTC of the organic material shown in Figure 1A;
Figure 2A is a front sectional view of another embodiment of the dual purpose reactor of the invention adapted for gasification involving a support means for burning coal and partly converted material and also illustrating the special variety of disposition of the agitator means / rods provided to support and work on the organic material fed to be treated;
Figure 2B is a side sectional view of the reactor of the Figure 2A;
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Figure 3A is a side sectional view of another embodiment of the dual use reactor of the invention adapted for carrying out low temperature conversion of the organic material;
Figure 3B is a side sectional View of the reactor of Figure 3A; Figure 3C is a top view of the reactor of Figure 3A;
Figure 4A is a front sectional view of yet another embodiment of the dual use reactor of the invention adapted for gasification and involving a grate type agitator means;
Figure 4B is a side sectional view of the reactor system of Figure 4A; Figure 4C is a top view of the reactor system of 4A;
Figure 5A is a top view of the upper grate used in the reactor system of Figure 4A;
Figure 5B is a top view of the middle grate used in the reactor system of Figure 4A;
Figure 5C is a top view of the lower grate used in the reactor system of Figure 4A;
Figure 6A & 6B illustrate variant of the lower grate suitable of use in the reactor system of the invention involving a fixed lower part (Figure 6A) and moveable upper part (Figure 6B).
Reference is first invited to Figure 1A which illustrate by way of a front sectional view the reactor system in accordance in the invention. As shown is said Figure 1A, the reactor is comprised of an upper chamber (1) and lower chamber (2) separated by means of rod like agitator means (3). According to this embodiment, the reactor system is adapted for gasification or LTC of the organic material. For the purpose the upper chamber (1) is shown to be fed with organic material (4) through and inlet (5) and by means of a hopper. The gaseous outlet (6) is shown provided in top for egress of the producer gas generated. The organic material (4) is shown blocking gases from flowing in and out of the reactor by forming a plug in the converging hopper (8).
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The feed material thus introduced rest on rod like agitator means (3) which are disposed substantially horizontally to separate the upper (1) and the lower chamber (2). The distance of the rods constituting the agitator means (3) is dependent on the material fed. For municipal solid waste; agro waste and biomass from forest and other type of organic material usually distant about 250 mm is preferred. In accordance with an aspect of invention the said rod like agitator means are adapted to rattle to agitate the material. The partly decomposed material thus fall in to the lower chamber.
As further illustrated in said figure in case of gasification the air is allowed to pass into the lower chamber (2) from the openings (7) at the bottom of the lower chamber (2). The ash resulting from combustion can also be removed from the reactor also through such openings (7).
The producer gas, which is emanating at the top of the upper chamber (1) can be burnt directly for process heat. In the alternative, the gas can also be cooled, purified and used for power generation in an internal combustion engine or gas turbine.
Reference is now invited to Figure 1B which illustrate in side sectional view the reactor system of Figure 1A. In this view the plurality of rods (3) separating the upper chamber (1) and the lower chamber (2) are further shown. Also the feed inlet (5) in the upper chamber (1) and also the air entry opening (7) at the lower end of the bottom chamber (2) are illustrated.
Reference is now invited to accompanying Figure 2A and 2B which illustrate further another embodiment of the dual use reactor system in accordance with the present invention. As illustrate in said Figure 2A in such modified arrangement while the basic features of the reactor remain the same as per the embodiment of Figure 1A, the agitator means that is the rod like agitator apart from involving the principal horizontally placed set of rods (3) also include additional rod/agitator (3A), (3B) and (3C) in the upper chamber (1). As shown in said Figure 2A such additional rods 3A and 3B are disposed at an angle upto 30° from the horizontal. Preferably, for gasification the lower chamber contains rods (3D) of small diameters preferably around 8 mm at the bottom above the outlet, distance is preferably around 50 mm. Such additional rods
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(3A/3B/3C/3D) can be provided fixed or moveabte like the nods (3) separating the upper and lower chamber.
Figure 2B illustrates the position of the rod (3) and air inlet openings (7) in the lower chamber (2) and the feed inlet (5) hi the upper chamber (1) in the side view.
Reference in now invited to. accompanying Figures 3A to. 3C which illustrate the reactor system of the invention adapted for low temperature conversion and generation of solid and gaseous fuel.
As illustrated in the Figure 3A, in this embodiment also the reactor is divided into upper chamber (1) and a lower chamber (2) by the substantially horizontally placed agitator means which are rod like tubular members (3). As distinct from the embodiment of Figure 1A for gasification, in this embodiment, for low temperature conversion, the agitator means / pipes (3) used for separating the upper and lower chamber are provided with holes/slits so that air can be supplied there through from outside into the middle of the bottom of the upper reaction chamber. Besides the slits in the rods or pipes (agitator means) the system can additionally incorporate Openings for air entry at the bottom of the lower chamber (2).
In this embodiment the doors (7) of the outlets at the bottom are usually kept close. The generated coal gather at the bottom of the lower chamber (2) and can be discharged from the outlet (7) from time to time by opening the doors. Water may be used to cool the removed fine hot coal. The coal bed in the lower chamber is further adapted to prevent air entering into the reactor from below during discharging. Provisions are provided for holding and rattling the rods from outside.
In case of low temperature conversion air is allowed to pass into the bottom of the upper chamber (1) for partly burning the gas and oil produced by the LTC in the lower chamber. In case of gasification such air passage that is the air flow in to the reactor is prevented by insulation with mineral wool and glass wool and any other material which is suitable.
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In case of the use of the reactor system for gasification and low temperature conversion, the hot gasses produced in the lower chamber and at the lower end of the upper chamber are used for drying, preheating and partly decomposing the material in the upper chamber. Therefore, in the reactor system of the invention no outside heating or fuel is required. Air can enter through natural thermal flow, no pressure or pre heating of the air is required. The producer gas which is emanating at the top of the upper chamber can be burnt directly for process. The gas can also be cooled, purified and used for power generation in an internal combustion engine or a gas turbine.
The reactor of the invention which include simple and cost effective means can be constructed of any suitable material such as steel, bricks, stones etc. or combination thereof. Preferably the reactor can be insulated by mineral wool, glass wool and any other suitable material. The shape of the reactor can be selectively provided in the form of rectangular cylindrical, conical, polygonal or a combination thereof.
Reference is now invited to Figure 4A to 4C which illustrate yet another embodiment of the reactor of the invention involving grate means as the separator between the upper and lower chamber and also as the agitator for effective processing of the organic material.
As shown in said Figure 4A while the basic constructional features of the reactor
remain the same as that the discussed in relation to earlier embodiment,
according to this embodiment, the agitator means is shown provided comprising
of rods and pipes obtaining of the form of grate (3). The grate may be fixed on a
vertical axis (3V) while the outer ends of the grate may be adapted to rest on a
support. The axis is fixed by rods to the walls of the reactor and / or the legs the
bottom of the reactor. Preferably, the vertical axis (3V) is connected to a lever
or a chain or any other drive for moving the axis back and forth or even rotating
the axis, rattling is however, preferred.
Figure 4B illustrate in side sectional view the reactor system of Figure 4A involving a grate type agitator means while Figure 4C is a top view of the whole grate type agitator incorporating reactor of Figure 4A.
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Reference is now invited to Figures 5A to 5C which illustrate in top view the configuration of the upper, middle and lower grate respectively in the grate type agitator used in the reactor of the Figure 4A. As would be evident from the illustration of the upper, middle and lower grates it is clear that the upper grate has the maximum opening in terms of flow path than the opening in the middle and the lower grates i.e. the flow paths available thorough the grates decrease from the upper to the lower grate.
Reference is now invited to accompanying Figures 6A and 6B which show a variant especially for gasification, of the grate at the bottom of the tower chamber comprise of a fixed grate with small distance rods which is intersected by more wide sectors. Above the fixed grate there is provided a wide grate which is moveable. This intersection of the lower grate is superceded by rods of the upper grate. So large pieces of ash or inorganic material are provided to pass through the grate on rattling or rotating the tipper grate. In this way the content of the organic material supported by the agitator / rod / grate means can be controlled along with the flow of gas and the reaction process by the reactor of the present invention.
In the above disclosed dual use reactor system of the invention, the feeding can be done manually or by mechanical devices like screw conveyers, piston pushing the material or by any other like suitable device. The agitating of the material and its processing can be control manually or by mechanical devices like pistons, chain wheel attachment to an axis with grate / rods / pipes or any other suitable agitator means. Likewise, the removal of ash on gasification or coal on low temperature conversion can be removed manually or mechanically by screw conveyors, belt conveyors and any other suitable device.
The above, therefore, clearly and sufficiently reveal the utilities and advantages of the dual purpose reactor system for gasification and low temperature conversion of organic base which is not only efficient in both the above varieties of conversion of biomass to valuable gas / solid fuel but also importantly avoid the need for any pre-drying (which is required only if the moisture content is above 35 % ) on the organic material before the conversion thereby making the processes simple and user-friendly. The system is also adapted such as to avoid complexities of mechanical moving parts and yet achieve fast and efficient
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partial combustion/gasification of the organic material. The system and in particular the selective and advantageous provision of simple agitator means adapted to separate the upper and lower chamber, support and control the organic material content and flow of gasses and the simple and user friendly manner of discharge of ash and solid fuel from the lower chamber outlet as and when applicable make it convenient to operate and use. The dual purpose reactor therefore would enable simple and easy conversion of variety of organic material into valuable fuel and can be widely used and applied for such purposes.
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WE CLAIM:
1. A continuous reactor for gasification or low temperature conversion for producing solid and gaseous fuels from organic starting materials comprising :
reactor unit comprising a lower chamber and an upper chamber disposed one above the other ;
agitator means selectively disposed preferably substantially horizontally to separate said upper and lower chambers and adapted to support the feed in the upper chamber and also agitate the feed and favour processing for effective partial combustion/gasification and incorporating provisions for air supply into said reactor, if required;
said upper chamber having means adapted for feeding in the organic material to be treated and for egress of the gaseous fuel generated upon partial combustion/gasification of the organic material;
said lower chamber at its lower end is provided with closable openings adapted to carry out atleast anyone of (i) open for discharge of the solid fuel/coal or ash as and when generated and (ii) allow entry of air into the bottom of the lower chamber as and when required.
2. A continuous reactor for gasification or low temperature conversion for producing solid and gaseous fuels from organic starting materials comprising :
reactor unit comprising a lower chamber and an upper chamber disposed one above the other ;
agitator means comprising selectively disposed preferably substantially horizontally placed agitator to separate said upper and lower chambers
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and adapted to support the feed in the upper chamber and also agitate the feed and favour processing for effective partial combustion/gasification and incorporating provisions for air supply into said reactor, if required, and additional agitator/rod means in the upper chamber preferably angled up to 30 degrees from the horizontal.
said upper chamber having means adapted for feeding in the organic material to be treated and for egress of the gaseous fuel generated upon partial combustion/gasification of the organic material;
said lower chamber at its lower end is provided with closable openings adapted to carry out atleast anyone of (i) open for discharge of the solid fuel/coal or ash as and when generated and (ii) allow entry of air into the bottom of the lower chamber as and when required.
3. A continuous reactor as claimed in anyone of claims 1 or 2 wherein said agitator means is selected from rods, pipes, tubular members, grates and comprise holes/slits for supply of air from outside to the region adjacent the bottom of the upper chamber preferably extending into the middle portion of bottom of the upper chamber in case of large size reactors.
4. A continuous reactor system as claimed in anyone of claims 1 to 3 wherein said means for feeding organic material in the upper chamber comprise inlets adapted for feeding preferably through hoppers with or without sealing provisions, said feed in the upper chamber preheated and partly gasified by the hot gases coming from below.
5. A continuous reactor system as claimed in anyone of claims 1 to 4 wherein for gasification the bottom openings of the lower chamber are adapted to allow air passsage therefrom into the reactor and also for ash disposal outlet, the partly decomposed material is burned in the lower chamber and the burning gases react with the material at the lower end of the upper chamber to form a producer gas.
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6. A continuous reactor system as claimed in anyone of claims 1 or 4 wherein for Low Temperature Conversion the lower chamber openings are adapted to be maintained air tight such as to maintain anaerobic conditions, the partly decomposed material forms coal and combustible gas, the produced gas removes the air, which initially is present, said agitator means adapted to pass air into the reactor at the lower end of the upper chamber whereby the produced gas is partly burned with air.
7. A continuous reactor system as claimed in anyone of claims 1 to 5 comprising outlet means for the combustible gas formed in the process for further processing.
8. A continuous reactor systemas claimed in anyone of claims 1 to 6 wherein the said agitator means/rods are adapted and selectively disposed to process unshredded material, the heap of material supported by said agitator means/ rods provided to controll the gas flow and therefore the reaction speed.
9. A continuous reactor system as claimed in anyone of claims 1 to 7 adapted to operate at relative low temperatures preferably the temperature in the upper chamber is upto 800C and in the lower chamber the temperature is upto 1000C on gasification and below 500C on Low Temperature Conversion.
10. A continuous reactor system as claimed in anyone of claims 1 to 8 wherein for gasification the feed opening means in the upper chamber cooperate with hoppers at the top whereby the material blocks gases from flowing in and out of the reactor by forming a plug in the converging hopper.
11. A continuous reactor system as claimed in claim 9 comprising for Low Temperature Conversion operation the coal bed in the lower chamber adapted to prevent air entering into the reactor from below during discharging.
12. A continuous reactor system as claimed in anyone of claims 1 to 10 wherein slits are provided for holding and rattling the agitator means/rods from outside manualy and/or by automatised means.
13. A continuous reactor system as claimed in anyone of claims 1 to 11 wherein the producer gas emanating at the top of the upper chamber is burned directly for process heat or cooled, purified and used for power
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generation preferably in an internal combustion engine or gas turbine.
14. A continuous reactor system as claimed in anyone of claims 1 to 12 wherein said disposition of the agitator/rods spaces therebetween its dimensions and nos. are baseds upon the feed and the process to be carried out gasification or Low Temperature Conversion.
15. A continuous reactor system as claimed in anyone of claims 1 to 13 wherein for Low Temperature Conversion the top inlet means of the upper chamber is adapted to be open, the material is fed from above and the produced gases are burned directly.
16. A continuous reactor system as claimed in anyone of claims 1 to 14 wherein said agitator means is in the form of grate means preferably adapted and fixed on a vertical axis, the outer end of the grate means adapted to optionally rest on a support, the axis being supported by rods to the wall of the reactor and/ or the legs at the bottom of the reactor and opionally said the vertical axis is operatively connected to a lever or a chain wheel or any other drive for moving the axis back and forth or rotating the axis, preferably rattling.
17. A continuous reactor system as claimed in claim 15 wherein for gasification the grate in the bottom of the tower chamber comprise of a fixed grate with small distance rods, which are intersected by more wide sectors, above the fixed grate there is a wide grate, which is movable, the intersections of the lower grate is superseded by rods of the upper grate such that large pieces of ash or inorganic material can pass through the grate on rattling or rotating the upper grate.
18. A continuous reactor system as claimed in anyone of claims 1 to 16 wherein said agitating means is adapted to be activated manually and/or mechanically preferably comprising devices selected from pistons, chainwheel attached to an axis with grates and rods or any other suitable device.
19. A continuous reactor system for gasification of organic starting materials comprising :
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a reactor unit Comprising a lower chamber and an upper chamber disposed one above the other ;
the upper and lower chambers separated by agitation means preferably a set of rods/grate members, said agitation/rod means adapted and disposed to facilitate the required agitation and flow of the feed under

gravity; said upper chamber having a feed inlet for the organic material to be treated and adapted such that the feed inlet can be kept dosed by. the
organic material fed into the reactor upper chamber and outlet means for the gaseous fuel generated upon partial combustion/gasification of the Organic material;
said lower chamber provided with support means for burning coal and partly converted material and also having at its lower end openings adapted to allow entry of air into the bottom of the lower chamber for gasification and also discharge of ash as and when required.
19. A continuous reactor system for low temperature conversion for producing solid and gaseous fuels from organic starting materials comprising :
a reactor unit comprising a lower chamber and an upper chamber disposed one above the other;
the upper and lower chambers separated by agitator means preferably a set of rods/grate members with provisions for air supply into the reactor, for said conversion, said agitator means adapted and disposed to facilitate the required agitation and flow of the feed under gravity;
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means in said upper chamber to feed the organic material to be treated and egress the gaseous fuel generated upon partial combustion/gasification of the organic material;
said lower chamber at its lower end is provided with closable openings adapted to carry out atleast anyone of (i) open for discharge of the solid fuel/coal as and when generated and (ii) allow entry of air into the bottom of the lower chamber.
20. A method for continuous gasification or low temperature conversion for producing solid and gaseous fuels from organic material comprising selectively adapting the continuous reactor as claimed in anyone of claims 1 to 21 and carrying out the process for gasification or Low Temperature Conversion substantially as hereindescribed.
21. A continuous reactor including a dual purpose such and method of gasification / Low Temperature Conversion using the same substantially as herein described and illustrated with reference to the accompanying examples.
22. A continuous reactor as claimed in anyone of claims 1 to 18 adapted for dual purpose use of carrying out gasification to generate producer gas and also for low temperature conversion of organic material into solid and / or gaseous fuels.
A continuous reactor for (i) gasification or (ii) low temperature conversion for producing solid and gaseous fuels from organic starting materials involving agitator means (3) selectively disposed preferably substantially horizontally to separate an upper (1) and lower chambers (2) of the reactor and adapted to support the feed in the upper chamber (1) and also agitate the feed and favour processing for effective partial combustion/gasification and incorporating provisions for air supply (7) into said reactor, if required. The said upper chamber (1) adapted for feeding in the organic material (4) to be treated and for egress of the gaseous fuel generated and said lower chamber (2) at its lower end is provided with closable openings adapted to carry out at least anyone of (i) open for discharge of the solid fuel/coal or ash as and when generated and (ii) allow entry of air into the bottom of the lower chamber as and when required. The reactor system is simple to operate and use and thereby meet the much required need in the art for such a dual purpose user-friendly reactors for conversion of organic materials.


Documents:

00132-kol-2005-abstract.pdf

00132-kol-2005-claims.pdf

00132-kol-2005-correspondence.pdf

00132-kol-2005-description(complete).pdf

00132-kol-2005-drawings.pdf

00132-kol-2005-form-1.pdf

00132-kol-2005-form-18.pdf

00132-kol-2005-form-2.pdf

00132-kol-2005-form-3.pdf

00132-kol-2005-letters patent.pdf

00132-kol-2005-p.a.pdf

00132-kol-2005-reply f.e.r.pdf

132-KOL-2005-(15-03-2012)-CORRESPONDENCE.pdf

132-KOL-2005-(15-03-2012)-FORM-27.pdf

132-KOL-2005-CORRESPONDENCE 1.1.pdf

132-KOL-2005-CORRESPONDENCE.pdf

132-KOL-2005-FORM 27 1.1.pdf

132-KOL-2005-FORM 27.pdf


Patent Number 207138
Indian Patent Application Number 132/KOL/2005
PG Journal Number 21/2007
Publication Date 25-May-2007
Grant Date 23-May-2007
Date of Filing 28-Feb-2005
Name of Patentee STEPHANI, TRUTZ-ULRICH
Applicant Address BUEHLWEG 19,77799 ORTENBERG,FEDERAL
Inventors:
# Inventor's Name Inventor's Address
1 STEPHANI, TRUTZ-ULRICH BUEHLWEG 19,77799 ORTENBERG,FEDERAL
2 JALAJ KUMAR CHATURVEDI A/7,VIP PARK KESTAPUR KOLKATA-700 101
PCT International Classification Number C10J 3/00
PCT International Application Number N/A
PCT International Filing date
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 NA