A rotary kiln is essentially a slow moving, i.e. rotating, refractory-lined steel cylinder. To facilitate the movement of waste material, it generally slants downward from the feed end to the outlet end. The kiln is heated to high temperatures and as material passes through the kiln, waste is evaporated, organic materials are volatized and combustion begins. Generally, rotary kilns can be designed to operate at temperatures between 1400 and 2600 degrees Fahrenheit. The kiln's end product can be either ash or slag, depending on the mode of operation and the initial characteristics of the waste that is fed to the kiln.
Key elements of rotary kiln design are the end seals, drive assembly, kiln refractory and control systems. The end seals are designed to minimize leakage of air into the system and prevent escape of combustion gases. The drive assembly must supply enough torque to rotate the kiln under all operating conditions. The refractory lining (tile) protects the kiln shell from overheating and chemical attack. At the same time, it provides a hot surface to aid in ignition and combustion of waste. Refractory surfaces near the feed inlet are designed for resistance to high impact and thermal shock loads. In the discharge area, refractory must withstand chemical attack and slag penetration.
In the inventive system disclosed and claimed herein using a rotary kiln of this invention, contaminated flue gas from waste combustion is used to heat clean air indirectly in a ceramic heat exchanger to temperatures up to about 2000 degrees Fahrenheit and clean air side pressures up to about 200 psig to run a gas turbine. No flue gas treatment is required, and the gas turbine can discharge clean air for process use rather than combustion products. The novel refractory tiles of this invention allow for the processing of waste without slag buildup and thus this invention eliminates one of the major problems associated with prior art kilns.
The invention herein destroys biomass and related wastes at their source and produces electrical power more efficiently than can be accomplished with conventional steam power plants. The system has low leakage in the heat exchangers used therein, and turbine efficiencies are high owing to the use of controlled maintenance air instead of combustion products.
Plants using the systems disclosed herein can be sized to handle large volume, low heat release, wet materials, at the source, to reduce trucking, storage, and related material handling situations. This process makes it possible for remote communities and industries to destroy municipal solid waste, sludge, wood products and trash and at the same time, generate electricity by firing a gas turbine with clean air.
The invention claimed herein deals with ceramic intermittently sealable refractory tile and controlled air continuous gasifiers that are manufactured using such refractory tile, and waste to energy systems that have such gasifiers as part of the system.
Thus, this invention deals in one embodiment with a ceramic intermittently sealable refractory tile comprising a refractory tile, said refractory tile having a top and a bottom. There is contained within the refractory tile, an air shaft, having an external end and an internal end. The external end is surmounted by a check valve and the internal end opens into a manifold formed in the top of the refractory tile. The manifold has a bottom, there being a plurality of channels from the bottom of the manifold that open through the bottom of the refractory tile.
Unlike the prior art kilns, the kilns of this invention have better control of the air through the fired bed; have customized tuyeres/permeable ceramic plates; eliminates the use of a ceramic ball valve; bears inexpensive construction, and can use standard, off the shelf check valves for safe operation.
It is important that those in the art recognize that the kilns of this invention have a counter-flow air flow pattern over the ash discharge section of the kiln which accomplishes three things that are important. First, the air cools the ash. Secondly, the air preheats the combustion air which it will be noted is introduced below the fuel pile, and thirdly, heated syngas transfers energy to the drying zone refractory lining. All other prior art kilns have an airflow pattern across all three sections of the kiln, which is inefficient.
In another embodiment, there is a ceramic, intermittently sealable refractory tile comprising a refractory tile, wherein the refractory tile is formed of air permeable ceramic. The refractory tile has a top and a bottom, and contained within the refractory tile is an air shaft, having an external end and an internal end. The external end is surmounted by a first manifold; the first manifold has an external end and an internal end. The external end of the manifold is surmounted by a check valve. The manifold internal end surmounts and joins to the external end of the air shaft. The internal end of the air shaft opens into a second manifold formed in the top of the refractory tile.
Yet another embodiment is a ceramic intermittently sealable refractory tile comprising a refractory tile, wherein the refractory tile has a top and a bottom. There is contained within said refractory tile, an air shaft that has an external end and a bifurcated internal end, wherein the external end of the air shaft has surmounted thereon a check valve. The internal ends of the air shaft exit through the bottom of the tile.
Still other embodiments of this invention are a controlled air continuous gasifier containing a plurality of refractory tiles of the type described just Supra and a waste to energy system employing a controlled air continuous gasifier.
Going to yet another embodiment of this invention there is a controlled air, continuous gasifier. The gasifier comprises (i) a cylinder having a feed end and a product end and comprising three zones consisting of zone A, a waste heating zone; zone B, a starved air combustion zone; and zone C, an ash cooling zone.
Component (ii) a feed end cap on the feed end of the cylinder and component (iii) is a product end cap on the product end of the cylinder.
Component (iv) is a product exit port in the product end cap and component (v) a flue gas exit port in the feed end cap.
Component (vi) is a waste feed port in the feed end cap and there is component (vii) which is at least one air injection port near the product end cap, the air injection port joining with an air manifold, wherein the air manifold is located outside any ceramic refractory tile of zones B and C and terminates at an upper end of Zone B.
Component (viii) is a means for allowing rotation of the gasifier. The cylinder comprises a. a refractory lined open center core running essentially the full length of the cylinder. The refractory lining has an inside surface and an outside surface; b. a first metal shell covering the entire outside surface of the refractory lining, the first metal shell having an outside surface; c. an insulated second metal shell formed adjacent to, and conforming to, the outside surface configuration of the first metal shell such that there is a hollow core provided between the first metal shell and the second metal shell, wherein the refractory lining of zone B is a ceramic sealable refractory tile as set forth just Supra.
Another embodiment of this invention is a waste to energy system comprising in combination at least a. a gasifier as described just Supra, b. an oxidizer; c. an air to air, all-ceramic heat exchanger; d. a gas turbine; e. a generator operated from the gas turbine and f. a filter and compressor driven by the gas turbine.
Yet another embodiment of this invention is a waste to energy system comprising in combination at least: a. a gasifier as disclosed just Supra; b. an oxidizer; c. an air to air, all-ceramic heat exchanger; d. a high pressure, medium temperature, alloy metal air-to air heat exchanger; e. a gas turbine; f. a generator operated from the gas turbine; and g. a filter and compressor driven by the gas turbine.
Turning now to the Figures, there is shown in
With reference to
With regard to
The feed enters this solid, refractory-lined zone that contains no air-cooling. The syngas from the combustion process contains primarily methane, hydrogen, carbon monoxide, carbon dioxide and water at a temperature below 800 dF. As this mixture passes over the feed, it drives off water, distills volatiles and heats the refractory in the preheat zone.
In addition, there is shown zone B, which is the starved air combustion zone, which constitutes on the order of about sixty to seventy percent of the interior volume of the cylindrical element 2. A percentage of the stoichiometric air is injected through the tuyeres into the fuel bed and combusts the fixed carbon to carbon monoxide. The rotation of the bed through the fuel introduces air continuously into the fuel as new fuel gently tumbles across the tuyeres as it moves downward to the exit. Because zone B is the combustion zone, this zone should be lined with a multiplicity of the inventive tiles of this invention.
Zone C is the ash cooling zone and this constitutes on the order of about twenty percent of the total interior volume of the cylindrical element 2. The air from the ash discharge housing bustle is introduced between the outer skin and the kiln shell at the ash housing. This air passes around the thin refractory-line kiln section and cools the ash indirectly as it passes over the kiln shell up to the combustion zone. Since this zone is not a combustion zone, the lack of direct air through the inventive tile 23 is acceptable, and thus, one need not provide this zone with a refractory tile of this invention and one can use standard tile 13 in this zone. However, as above, the particular process may require the use of the inventive tile of this invention in this zone and such a use is contemplated within the scope of this invention.
The above-described arrangement is the direct opposite arrangement of the gasifier and process described in U.S. Pat. No. 6,381,963, In that design, the air starts at the preheat zone and flows into the combustion zone, and continues on through the ash zone. Therefore, it cools the preheat zone and heats the ash zone using energy that it picked up from the entire length of the kiln as it travels from the feed end to the ash discharge housing. In the inventive process, the air is introduced at the ash discharge housing and taken off before it reaches the preheat zone.
Thus, it is contemplated within the scope of this invention to use a multiplicity of the inventive tile in the refractory lining 8 in combination with standard tile 13, and it is also contemplated within the scope of this invention to provide for the whole of zone B to be made up of the inventive tile. The designation 13 denotes standard fire brick, but is also used to shown standard fire brick construction material, such as in
During processing, air is introduced into the air conduction system 9, and the air is allowed to move through the air conduction system 9. However, a certain portion of the air is conducted to zone B, wherein it moves into the inventive refractory tiles through open air shafts, all of which will be discussed infra. The movement of the air in this manner differs from some of the prior art, in which air is introduced directly into the cylindrical element 2 through the product end cap 4, and directly into the combustion zone B and on through the zone A and out the exit 5.
When air is introduced as stated in the prior art. The method is ineffective in that a lot of the air moves through the gasifier and exits with the flue gas and is lost. Also, the control of combustion is difficult in that the air is not moved to the combustion mass in a constant and consistent manner such that the rate that each portion of the combusting mass uses is inconsistent and therefore, the combustion is inconsistent and permits the huge build up of slag. Removing the slag is a major problem and often leads to a clogged gasifier and provides other major problems, including a large amount of ash that has to be collected and handled.
It should be noted by those with ordinary skill in the art, that the gasifier is normally tilted such that the feed end of the gasifier is higher than the product end. This is to facilitate the movement of the waste through the gasifier 1 as the gasifier 1 rotates during operation. Normal rotation for a gasifier is clockwise.
Turning now to
There is a second metal shell 17, which is a metal cover 18 over insulation 19 over the entire cylindrical portion 2 of the gasifier 1. The placement of the first metal shell 16 and the second metal shell 17 is such that a hollow air conduction system 9 is formed essentially from the tail end of zone C (point 20) to the leading edge (top) of zone B (point 21), wherein zone B is bustled at point 21 to prevent the transfer of any air into the feed area in zone A (see
Zone B is the preferred zone for the use of the inventive tiles herein although, it is contemplated within the scope of this invention to use the inventive tile 25A-C in zones A and C as well, depending on the type of waste that is being processed, among other factors. It has been found that inventive tile 25A is best when processing litter such as biomass litter; tile 25B is best when processing municipal solid waste, and tile 25C is best used when processing sludge such as sewage sludge, and the like.
There is shown a certain amount of waste matter 22 in the bottom of the gasifier 1 in zone A that is being processed. As will be discussed infra, the valves 26 of the sealable tiles 25A-C of this invention open when the tiles 25A-C arrive at approximately point D, shown on
Preferred for this invention are refractory tiles 25A-C that are put together using two halves. Thus, when the tiles are molded from ceramics, they are usually molded in halves and joined together by mortar to form the whole tile 25A, 25B or 25C.
Turning to
Turning now to
Turning now to
Turning now to a third embodiment of the inventive tile herein, there is shown in
The tile 25C is constructed of air permeable ceramic 35 in the core. This tile is intended to be used in conjunction with several other tiles sharing one common air manifold 32 as is shown in
In addition to the advantage obtained by the use of the valve control of air, there is also another feature that adds to the efficiency of the unit.
It should be noted that tuyeres or jet nozzles can be used on the exit ports of the tiles of this invention and it is contemplated within the scope of this invention to equip the tiles with such tuyeres and jet nozzles, depending on the type of material being combusted. For purposes of this invention, jets and nozzles as used herein means those shown in “Engineers' Illustrated Thesaurus, by Herkimer, H., Wm. Penn Publishing Corp., New York, N.Y., Chemical Publishing Co., Inc. pages 348 and 349, wherein there is shown a multiplicity of nozzles and jets, it being understood that the criticality of the nozzle herein is that the air delivery system of this invention is a blast tuyere and is not a single point of exit from the air shaft, reference is made to jet E, blast tuyere and jet A, Rose jet for spreading.
The tiles of this invention are made from silicon carbide/nitride. They are easily cleaned, they are hard and ash releases from them readily. The refractory core is therefore easy to build, and is easily retrofitted.
For purposes of this invention, waste to energy systems are those set forth in U.S. Pat. No. 6,381,963, that issued May 7, 2002 to the inventor herein and such waste to energy systems, their individual components, make up, use and control are incorporated herein for what is taught about such systems.
This application claims priority from U.S. Provisional patent application 60/937,310 filed Jun. 27, 2007. The invention disclosed and claimed herein deals with ceramic intermittently sealable refractory tile and controlled air continuous gasifiers (rotary kilns) that are manufactured using such refractory tile, and waste to energy systems that have such gasifiers as part of the system. The refractory tile and the novel controlled air continuous gasifiers of this invention form part of a system that is novel and environmentally effective to directly convert the latent thermal energy of biomass waste to power (electricity or steam) without the need for costly processes to clean contaminated flue gases. This application is an original application claiming priority from U.S. Provisional patent application Ser. No. 60/937,310, filed June 27, 2007.
Number | Date | Country | |
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60937310 | Jun 2007 | US |