The present disclosure relates to a process and equipment to process sorted and unsorted municipal solid waste (hereinafter “MSW”) to produce energy, typically in the forms of electricity or heat. The system process allows for the maximum amount of energy to be retained, hydrocarbons to be driven from the MSW and syngas with an increased BTU value to be produced. This disclosure provides processes, methods and equipment to enhance the BTU value, or quality, of the syngas produced as well as significantly reduce the overall volume of waste. The waste can be reduced by up to 95% of its original volume while simultaneously reducing greenhouse gas emissions by up to 95%.
The present disclosure is directed to reactor designs optimized for thermal decomposition of MSW, particularly MSW containing both loose items and cylindrical compressed bales of MSW.
There are numerous methods to convert MSW to energy, from thermal decomposition, thermal degradation, gasification, plasma arc to liquification. Each of these methods reduces MSW and produces a gas and/or latent heat to generate energy.
Thermal decomposition can process unsorted MSW and produce heat that is used to operate boilers which in turn operate turbines to produce electricity.
Gasification usually involves sorting the MSW, sizing (usually, grinding), drying and reforming the raw MSW into pellets prior to feeding into the gasification unit.
Pyrolysis generally involves sorting to remove unsuitable materials, then heating in the absence of oxygen resulting in the breakdown of the MSW into liquid hydrocarbons and syngas.
Unfortunately, landfilling is currently the most popular method of disposing of waste. This disposal method involves little capital investment to simply transport the waste to a suitable location to be dumped and covered. Additionally, municipal solid waste is currently one of the largest single producers of the greenhouse gas, methane, from countless landfills. The gas is generated from decomposing waste and it seeps into the atmosphere continually.
Clearly there is a need for a process, and equipment to carry out the disposal process which will convert the large amounts of MSW into a green energy source while also reducing the volume of the MSW.
The present disclosure is directed to canisters to hold waste feedstock, and autoclaves specially designed to process the waste at suitable temperature and pressure combinations. Disclosed is a reactor for thermal processing of waste materials including a canister having an interior defined by a wall with at least one support structure mounted on the wall, and at least one compression relief structure pivotally attached to a respective one of the support structures. The compression relief structure is pivotable between a first position that is parallel to the wall, and a second position that is orthogonal to the wall.
The compression relief structures can pivot out of the way when MSW is initially loaded into the canister, then pivot to a position orthogonal to the interior wall to prevent compression of the loaded MSW when even more MSW is loaded into the canister. With one or more support structures mounted on the interior wall, and the compression relief structures pivoted to the orthogonal position, the compression forces on the MSW loaded into the canister are decreased.
Additionally, disclosed is a canister or reactor for the thermal processing of waste material made up of a canister, a floor structure at the bottom of the canister, a heated air opening located in the floor structure in the canister, and a conical structure centrally positioned above the heated air opening. A carbon pillow can be positioned around the conical structure and configured to prevent the heated air from directly contacting the waste material. As used herein, a canister generally refers to a cylindrical shaped vessel.
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the detailed description serve to explain the principles of the invention. The drawings represent an illustration of some of the embodiments of the present invention and are not to be construed as limiting the scope of the invention in any manner. Some of the drawings may not show all of the features and components of the invention for ease of illustration, but it is to be understood that where possible, features and components from one drawing may be included in the other drawings. Further, the drawings are not necessarily to scale, some features may be exaggerated to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention. In the drawings:
In the presently disclosed system, the MSW can be received in either loose or baled. In either case, the material can be placed inside cylindrical canisters which are then placed inside an autoclave to be thermally processed. One feature of the presently disclosed system is when baled MSW is processed there is no need for the bales to be opened prior to being placed into a canister section, that is, the entire compressed bale can be placed into the canister section as received from the baler. The canister can be loaded with either a bale of MSW or loose MSW, or in some cases, a mixture of the two, and then lifted into the autoclave and placed into position.
In some instances, it may be preferable to first place loose MSW in the canister and then add a bale of compressed MSW. In order to prevent the bale from compressing the loose MSW and negatively impacting the completeness of its thermal conversion, the presently disclosed compression relief structures can be utilized to prevent the unwanted compression by holding the bale above the loose MSW. In other instances, the compression relief structures can be utilized between two or more bales of compressed MSW. In many such embodiments, liquid wastes can be added to the canister. In yet other instances between larger pieces of refuse such as, for example, tires, furniture, appliances, and so forth.
The compression relief structures can be pivotably, rotatably and detachably attached to support structures that can be mounted in various configurations in the presently disclosed canister. In some embodiments, the support structures 140, 142, 144, 146 can be mounted in the midplane 130 of the canister as illustrated in
For some embodiments of the present disclosure, there can be 2, 3, 4, or more support structures for the compression relief structures symmetrically arranged around the internal circumference of the canister. In other embodiments, the support structures for the compression relief structures can be in a nonsymmetrical arrangement about the internal circumference of the canister.
In various other embodiments of the present disclosure, the compression relief structures can be positioned in an angled position between the first plane 108 and the second plane 110. In other embodiments, the compression relief structures can be located in more than two planes, or in other arrangements can be in non-planar arrangements.
In other embodiments of the present disclosure, the support structures can be replaced with openings in the canister wall to allow for the compression relief structures to enter the opening, span the canister, and then insert into a corresponding opening on the opposite interior wall of the canister. The two corresponding openings can be diametrically opposed to one another or can be non-antipodal. in some embodiments, the compression relief structures will cross the center of the canister. In some embodiments of the presently disclosed canister, the compression relief structures can enter an opening in one plane 108 and insert into an opening in another plane 110, and vice versa. Prior to installation into the autoclave the openings can be closed with appropriate closing structures.
In some embodiments of the present teachings, the canisters are further equipped with compression relief structures 100 to prevent further unwanted compression of waste materials loaded into the canister. In some embodiments, the compression relief structures 100 can be located at two levels of the canister 170, one level 108 at approximately one-third of the canister height, and a second level 110 at approximately two-thirds of the canister height. In other embodiments of the present teachings, there can be more levels of relief structures 100 positioned at different heights inside the canister 170. For instance, the relief structures 100 can be arranged in a “staircase” arrangement spiraling up and around on the inside of the canister, or “randomly” staggered arrangements can be utilized. In other embodiments of the present disclosure, the compression relief structures can be located or spaced in irregular or random locations on the interior of the canister to provide flexibility to the loading of the canister with MSW.
The compression relief structures 100 can be attached to the inside wall of the canister so that when the canister is in an upright vertical position for loading of MSW, loose or baled, the compression relief structures 100 will pivot to a parallel orientation to the interior wall so that the movement of the MSW to the bottom of the canister is not impeded. The compression relief structures 100 can then pivot to an orientation orthogonal to the interior wall, and thus prevent compression of the MSW already loaded below the compression relief structure. After thermal chemical processing of the MSW, the canister can be rotated to an inverted vertical position, and the compression relief structures 100 can fold up against the inside wall, or pivot back to the parallel orientation to the interior wall so that the movement of the processed MSW out of the canister is not impeded.
Thus, in the various embodiments of the present disclosure, when the canister is inverted to remove the contents therein, the compression relief structures can fold up against the inside wall to allow all of the contents to exit the canister. Those of skill in the art will recognize various ways to achieve the desired actions of the compression relief structures 100.
The exemplar embodiment illustrated in
The exemplar embodiment illustrated in
As illustrated in
In some embodiments, the compression relief structures can be a solid structure as shown in
In some embodiments, a retaining mechanism can be incorporated into the overall support structure to maintain the compression relief structure in a vertical or parallel to the wall orientation. Exemplary retainer mechanisms can include retainer pins or stops in the support structure 102, or spring loaded mechanisms. One of ordinary skill in the art would recognize the possible retaining mechanisms that would perform under the operating conditions of the canister.
The combined horizontal lengths of diametrically opposing compression relief structures 100, for instance, at positions 140 and 144, or positions 142 and 146, or positions 160 and 164, or positions 162 and 166, can be equal to 99%, 90%, 80%, 70%, 60%, 50%, 40%, 30%, 20%, 10%, or 5%, respectively, of the inside diameter of the canister 170. In some embodiments, the combined lengths of opposing relief structures 100 can be equal to any number between 5% and 99% of the inside diameter of the canister 170.
An overview of one embodiment of the present teachings is provided in
Components of the cylindrical canisters can be assembled of stainless steel or low carbon steel depending on the structural requirements of the environment. The grates, support structures, and the compression relief structures can be composed of, for example, low carbon steel, stainless steel, or other suitable steel or metal alloys.
Temperatures and pressures during the thermal conversion process can be monitored by means of heat and pressure sensors located throughout the autoclave. The sensors can be located at the top dome, the top, middle and bottom of the canister, the inner shield and the various process lines entering and leaving the autoclave. The sensors can be installed using known methods through the walls of the autoclave to allow for measurements of reactor conditions during the thermal conversion process.
One embodiment of the presently disclosed process involves placing a carbon pillow into the bottom of the canister to provide a layer between the ignition gas and the MSW. The carbon can be ignited by the heated air, and thereby turn into a thermal layer. Thus, the MSW is not contacted directly with the heated air from the heater but rather the carbon pillow is ignited which in turn begins the thermal conversion of the MSW. During downdraft cycles, the thermal layer will still continue upwards thru the MSW while the process gases will pass down thru the carbon layer. It is understood that as the gases pass through the carbon layer any aromatic cyclical hydrocarbon ring compounds present can be broken down.
The bottom of the canister in the autoclave can be located directly above the gas heater chamber. In some embodiments of the presently taught system, the top of the gas heater chamber can be equipped with a solid metal ring 450 to enable the thermal decomposition process to be started and maintained more easily. The plate can have an appropriately sized hole in the middle thereof to allow for proper ventilation of the gas heater area. A canister section can have a grate 410 or wire mesh 430 assembly at its end portion. The grid properties can vary dependent on the properties of the MSW contained in the canister section. This arrangement is illustrated in more detail in
The heated air chamber located at the bottom of the autoclave can be equipped with a conical shaped heat deflector which can be composed of an appropriate metal to withstand the conditions, for instance, stainless steel. The heat deflector or conical structure 180 can be in a fluted cone shape as shown in
As shown in
The carbon pillow can be composed primarily of charcoal. The carbon pillow (not shown) can be positioned around and over the conical structure 180 and over the grated floor structure 430. The carbon pillow can be thick enough that the heated air does not directly impact the solid waste material during the initial start-up operation of the thermal decomposition process. For illustrative purposes, in some instances, the carbon pillow can be ten inches or more in depth. The solid waste material is thermally converted to syngas during the presently disclosed thermal decomposition process, and does not come into direct contact with the heated air.
The canister can have a perforated or grated floor bottom structure (see 410, 430 and 450 of
The canister can be equipped with air vents 120 at appropriate locations to control the thermal reaction within the canister. These air vents can be set, in some instances, to a desired level prior to the insertion of the filled canister into the autoclave. In some embodiments of the canisters, the top of the canister and the vents 120 can both, independently of one another, be present during the thermal decomposition process.
One possible embodiment of the presently disclosed autoclave or MSW processor is further illustrated in
The cylindrical canisters can be sized to accommodate bales of compressed MSW. These bales typically weigh from between 1000 to 2600 pounds. The bales can be produced in various dimensions. Typically the bales are 3 to 5 feet high, but can be as tall as 12 feet high, the bale diameter can be about 4 to 5 feet. The presently disclosed system is not limited to a certain size or dimension of the baled MSW but can be sized, larger or smaller, to accommodate the size of the available bales. Properties such as conversion efficiencies or increased BTU value of the gas may be impacted by the bale size.
In some embodiments of the present teachings, the MSW can be baled without sorting of the waste, and in other embodiments the waste can be sorted on the basis of its BTU content. Thus, high density BTU waste materials, plastics and rubber-containing items, like tires, can be separated from lower density BTU waste material like newspaper, food or yard waste. The separated items can be compressed into separate bales, or in some embodiments, the separated items can be re-mixed to obtain an MSW mixture with an average baseline BTU content in each bale.
Similar to the various waste materials added to the bales, liquid waste materials can also be added to both baled and unbaled MSW alike. Liquid wastes such as used motor oils or lubricants can increase the BTU content of the waste material.
In some embodiments, unsorted MSW can be then loaded into a canister which in turn is placed into the autoclave. The waste can be placed loosely into a canister and/or compressed bales may be placed into the canister. Preferably the bales are cylindrical and sized to fit in the canisters of the present teachings. The bales can be compressed between 100 and 1000 psi, and then wrapped in a protective material to maintain the compressed condition.
The various waste feedstreams leading into the baler can include a variety of possible separated recycled or refuse components including food wastes, lawn and garden waste, plastics, rubber, liquid oil, grease, lubricants, processing liquid wastes, or other hydrocarbon-containing liquids or gels.
In some instances, larger size metal pieces can be introduced into the material to be baled. One reason for adding the metal pieces is to minimize dead zones inside the bale where material does not readily thermally decompose. This phenomenon is seen on an irregular basis during the presently disclosed process. While the exact mechanism of why decomposition does not occur has not been fully developed, it is currently understood that the introduction of void spaces can increase the efficiency of the decomposition process and decrease dead zones. The addition of the metal pieces can increase void spaces, also provide hot spots and increase conduction of thermal energy into more densely packed waste material.
The EPA (U.S.) broadly defines MSW as containing “everyday items such as product packaging, yard trimmings, furniture, clothing, bottles and cans, food, newspapers, appliances, electronics and batteries.” Typical sources of MSW include residential, commercial, and institutional sites. Although, the EPA's definition excludes industrial, hazardous, and construction and demolition waste, such as rubble, for the present disclosure such wastes, including tires, are included in the definition of MSW. When handling certain classes of MSW, handling safeguards should be implemented to avoid undesirable side effects and contamination arising from the wastes.
A reactor for the thermal decomposition of waste material is also taught by the present disclosure. The reactor can contain a canister, a floor structure at the bottom of the canister, a heated air opening for heated air introduction located in the floor structure in the canister, and a conical structure centrally positioned above the heated air opening. The present reactor can be placed into an autoclave suitable of holding the canister.
The conical structure centrally positioned above the heated air opening can have a carbon pillow positioned around the conical structure, and be configured to prevent the heated air from directly contacting the waste material. As set forth above, the carbon pillow can be, in some embodiments of the presently disclosed system, ten inches or more thick. One purpose of the carbon pillow is to prevent direct impact of the heated air on the compressed or loose MSW.
In some embodiments, the canister can have a floor structure comprising a grated structural component configured to allow for airflow and support for the waste material. Of particular interest is preventing partially thermally decomposed material from falling out of the canister.
For the canister, the floor structure can be a solid plate having a central heated air opening, and in some cases, a grated structural component can be located above the solid plate and its central heated air opening.
As set forth above, provisions can be made for introducing additional air and water into the disclosed reactor to control the thermal decomposition process, thus the canister can include openings for venting of process gas, or introduction of additional reaction components.
A sealable reactor vessel generally suitable for used with the presently disclosed method can include the apparatus generally described in the applicant's prior patent, U.S. Pat. No. 8,715,582 B2, the disclosure of which is incorporated by reference herein in its entirety for all purposes.
All publications, articles, papers, patents, patent publications, and other references cited herein are hereby incorporated by reference herein in their entireties for all purposes.
Although the foregoing description is directed to the preferred embodiments of the present teachings, it is noted that other variations and modifications will be apparent to those skilled in the art, and which may be made without departing from the spirit or scope of the present teachings.
The foregoing detailed description of the various embodiments of the present teachings has been provided for the purposes of illustration and description. It is not intended to be exhaustive or to limit the present teachings to the precise embodiments disclosed. Many modifications and variations will be apparent to practitioners skilled in this art. The embodiments were chosen and described in order to best explain the principles of the present teachings and their practical application, thereby enabling others skilled in the art to understand the present teachings for various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the present teachings be defined by the following claims and their equivalents.
The present application is a continuation-in-part application claiming benefit from earlier filed U.S. patent application Ser. No. 16/796,633, filed Feb. 20, 2020, now U.S. Pat. No. 11,584,893, issued Feb. 21, 2023, which claims priority from U.S. Provisional Application No. 62/807,798, filed Feb. 20, 2019, all of which are incorporated by reference in their entireties for all purposes.
Number | Date | Country | |
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62807798 | Feb 2019 | US |
Number | Date | Country | |
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Parent | 16796633 | Feb 2020 | US |
Child | 18172241 | US |