Process for reforming inflammable gas, apparatus for reforming inflammable gas and gasification apparatus

TECHNICAL FIELD

[0001] The present invention relates to a combustible gas reforming method and a combustible gas reforming apparatus for reforming a combustible gas produced by a gasification apparatus which gasifies combustible materials such as coal, biomass, municipal wastes, industrial wastes, RDF (refuse-derived fuel) and waste plastics, and a gasification apparatus.

BACKGROUND ART

[0002] A gasification and slagging combustion furnace which has been developed as a technology for incinerating wastes or the like converts wastes into a combustible gas in a gasification apparatus and immediately combusts the combustible gas, thereby achieving high-temperature combustion. The high-temperature combustion is advantageous in that ash is reduced in volume and made harmless by being melted, and the combustion efficiency is improved (unburned combustibles in the incineration ash are reduced and the amount of exhaust gas is reduced due to low-temperature air ratio operation). However, the high-temperature combustion is problematic from the standpoint of energy utilization in that there is a limit to efficiency because all the energy is converted into heat as with a conventional incinerating furnace, and energy which is conservable cannot be produced.

[0003] In view of the above drawbacks, there has recently been developed a technology for utilizing a gas generated by a gasification apparatus (hereinafter referred to as “generated gas”) as a “gas” to the utmost, rather than combusting the gas. The produced gas (hereinafter referred to as “product gas”) is used as a fuel for a gas turbine, a gas engine, and an electric generating apparatus such as a fuel cell, or as a material for synthesizing a liquid fuel.

[0004] A cogeneration system which combines the generation of electricity by utilizing a product gas and the generation of electricity by heat recovery improves the energy utilization efficiency, and is being developed not only in the field of wastes, but also in the field of thermal power generation as a highly efficient coal fired power generation technology. The technology of utilizing a product gas as a material for synthesizing a liquid fuel will contribute to energy security in the future because conservable energy can be produced from energy resources which have heretofore been thrown away.

[0005] The technology for extracting a generated gas as a product gas was present in the past. However, since a gas produced by gasifying combustible materials in a low temperature range was used as it was at that time, the handling of a tar (macromolecular hydrocarbon: deposited at 400° C. or lower and causing fouling trouble) and a char (which is combusted when being in contact with oxygen at high temperatures because it contains fixed carbon) posed problems, which have been responsible for preventing the technology from finding practical use.

[0006] According to the present gas utilization technology, in order to avoid the above tar problem, a high-temperature gasification apparatus (operable at a temperature of 1000° C. or higher) is provided at a subsequent stage of a low-temperature gasification apparatus (operable at a temperature of 500° C. to 900° C.), and a generated gas produced by the low-temperature gasification apparatus is reformed with an oxidizing agent (oxygen, steam) in the high-temperature gasification apparatus. Since this process is a two-stage (low temperature+high temperature) gasification process, part of the generated gas produced by the low-temperature gasification apparatus in the first stage is combusted. While the above tar problem can be solved by the process, the energy utilization efficiency is lowered because part of the generated gas is converted into thermal energy.

[0007] Use of a catalyst has been considered to solve the above tar problem. The purpose of using a catalyst is to suppress an energy loss that is caused at high temperatures by promoting a decomposition reaction with the catalyst in such a temperature range in which the tar would normally be less liable to be decomposed.

[0008]
FIG. 1 of the accompanying drawings is a diagram showing a construction of a gas reforming apparatus for carrying out a conventional combustible gas reforming method which uses a catalyst. In FIG. 1, reference numeral 301 represents a gasification apparatus which gasifies a raw material A such as coal, biomass, municipal wastes, industrial wastes, RDF, waste plastics, etc. A generated gas GA produced by the gasification apparatus 301 is reformed (tar decomposition) into a product gas GB by a gas reforming apparatus 302 which uses a catalyst CA. The catalyst CA which has contributed to the reformation of the generated gas GA is turned into a degraded catalyst CA′, which is delivered to a catalyst regenerating apparatus 303. In the catalyst regenerating apparatus 303, the degraded catalyst CA′ is heated or regenerated by catalyst regenerating heat TE caused by external energy or combustion of part of the generated gas. The heated or regenerated catalyst CA is transferred again to the gas reforming apparatus 302.

[0009] As described above, the catalyst regenerating heat TE is required for the catalyst regenerating apparatus 303 to heat or regenerate the catalyst. Heretofore, the catalyst regenerating heat TE has been produced by combustion of part of the generated gas GA or external energy such as fossil fuel, electricity, etc. Even if the gas reforming can be performed at a low temperature by using a catalyst to reduce thermal energy loss, energy of high quality is utilized likewise for heating or regenerating the catalyst, and hence the advantages of low-temperature reaction cannot be sufficiently utilized. Therefore, even though the gas reforming process is highly efficient, since the overall amount of consumed energy is increased, the running cost is increased, resulting in a reduction in the evaluation according to LCA. As the process becomes higher in efficiency, the evaluation according to LCA or exergy (the quality of energy), rather than a simple thermal efficiency, becomes important.

[0010] In the case where the gas reforming is performed using the catalyst, the supply of heat in the temperature range of 1000° C. or less is sufficient differently from the reforming by the high-temperature gasification apparatus, and hence external energy having high quality as energy or combustion of the generated gas is not always necessary. Thus, it is necessary to construct a catalyst reforming process on the basis of the fact that heat required for heating or regenerating the catalyst can be supplied through a heat transfer surface or a medium.

DISCLOSURE OF INVENTION

[0011] The present invention has been made in view of the above problems. It is therefore an object of the present invention to provide a combustible gas reforming method and a combustible gas reforming apparatus which improve energy utilization efficiency for catalyst regeneration in reforming a gas with a catalyst and facilitate handling of the catalyst in a process for gasifying combustible materials including coal, biomass, municipal wastes, industrial wastes, RDF, waste plastics, etc. with a gasification apparatus and reforming the generated gas into a product gas. That is, it is an object of the present invention to provide a gasification furnace which can suppress generation of tar to a minimum to stably produce a generated gas having an excellent property, and can produce a generated gas capable of being utilized for the recovery of power at high efficiency, power generation, various liquid fuel synthesis processes, and various chemical material synthesis processes.

[0012] Another object of the present invention is to provide a combustible gas reforming method and a combustible gas reforming apparatus which improve the energy utilization efficiency in catalyst regeneration and gas reforming, and facilitate handling of the catalyst.

[0013] In order to achieve the above objects, according to the invention defined in claim 1, there is provided a combustible gas reforming method comprising: gasifying combustibles in a gasification apparatus; reforming a generated gas produced by gasification in a gas reforming apparatus using a catalyst to produce a product gas; and regenerating the catalyst degraded in the gas reforming apparatus in a catalyst regenerating apparatus; wherein waste heat of the combustible gas reforming process is used as a heat source for regenerating the catalyst in the catalyst regenerating apparatus and/or a heat source for heating.

[0014] According to the invention defined in claim 2, there is provided a combustible gas reforming apparatus comprising: a gasification apparatus for gasifying combustibles; a gas reforming apparatus for reforming a generated gas produced in the gasification apparatus using a catalyst to produce a product gas; and a catalyst regenerating apparatus for regenerating the catalyst degraded in the gas reforming apparatus; wherein the catalyst regenerating apparatus uses waste heat of the combustible gas reforming process as a heat source for regenerating the catalyst.

[0015] As described above, the waste heat of the combustible gas reforming process is utilized as the heat source required for catalyst regenerating heat in the catalyst regenerating apparatus and gas reforming reaction in the gas reforming apparatus, or the catalyst regenerating apparatus which uses the waste heat of the combustible gas reforming process is used. Therefore, a heat source having a low value such as the sensible heat of exhaust gas that is generated in a gasification process of a raw material can be used as the heat source for regenerating the catalyst or the heat source for gas reforming. Thus, since any external energy or the heat of combustion of the generated gas may be reduced or eliminated, the yield of the generated gas can be increased. As a result, the overall efficiency can be increased. The overall amount of consumed energy is thus reduced, the running cost is low, and an LCA evaluation is high.

[0016] According to the invention defined in claim 3, there is provided a combustible gas reforming method comprising: gasifying combustibles in a gasification apparatus; reforming a generated gas produced by gasification in a gas reforming apparatus using a catalyst to produce a product gas; and regenerating the catalyst degraded in the gas reforming apparatus in a catalyst regenerating apparatus; wherein char (unburned carbon) produced by gasifying the combustibles in the gasification apparatus is combusted in a char combustion apparatus, and the heat of combustion of the char is used as a heat source for regenerating the catalyst in the catalyst regenerating apparatus and/or a heat source for heating.

[0017] According to the invention defined in claim 4, there is provided a combustible gas reforming apparatus comprising: a gasification apparatus for gasifying combustibles; a gas reforming apparatus for reforming a generated gas produced in the gasification apparatus using a catalyst to produce a product gas; and a catalyst regenerating apparatus for regenerating the catalyst degraded in the gas reforming apparatus; wherein a char combustion apparatus is provided for combusting char (unburned carbon) produced by gasifying the combustibles in the gasification apparatus, and the catalyst regenerating apparatus uses the heat of combustion of the char generated in the char combustion apparatus for heating and regenerating the catalyst.

[0018] As described above, the char produced by gasifying the combustibles in the gasification apparatus is combusted in the char combustion apparatus, and the heat of combustion of the char is used as the heat source required for the catalyst regenerating heat or the gas reforming reaction in the gas reforming apparatus. Because any external energy or the heat of combustion of the generated gas may be reduced or eliminated, the yield of the generated gas can be increased. As a result, the overall efficiency can be increased. Specifically, the catalyst can be regenerated without combusting part of the product gas or without using external energy. Since the heat of combustion of the char, which is higher in temperature than the waste heat of the combustible gas reforming process, is used, the efficiency of heating and regenerating the catalyst is increased. Therefore, the overall amount of consumed energy is reduced, the running cost is low, and an LCA evaluation is high.

[0019] According to the invention defined in claim 5, there is provided a combustible gas reforming apparatus comprising: a gasification apparatus for gasifying combustibles; a gas reforming apparatus for reforming a generated gas produced in the gasification apparatus using a catalyst to produce a product gas; and a catalyst regenerating apparatus for regenerating the catalyst degraded in the gas reforming apparatus; wherein the gasification apparatus comprises a gasification chamber and a combustion chamber each having a fluidized bed, the gasification chamber being constructed to gasify the combustibles to produce a generated gas and the combustion chamber being constructed to combust char (unburned carbon) produced by gasifying the combustibles; and wherein the generated gas produced in the gasification chamber is delivered to the gas reforming apparatus and reformed in the gas reforming apparatus, and a combustion exhaust gas from the combustion chamber is delivered to the catalyst regenerating apparatus to heat and regenerate the catalyst with the heat of the combustion exhaust gas.

[0020] As described above, the gasification chamber and the combustion chamber each having a fluidized bed are integrated into a furnace. In addition to the effect of the invention of claim 4, the gasification apparatus has a function to gasify a raw material and a function to combust char. Since char generated in the same apparatus is combusted, any trouble caused by the delivery of the char is avoided. Since the raw material is gasified in the fluidized bed and the char is combusted in the fluidized bed, the diffusion of heat is excellent, and stable operation can be performed.

[0021] According to the invention defined in claim 6, there is provided a combustible gas reforming apparatus comprising: a gasification apparatus for gasifying combustibles; a gas reforming apparatus for reforming a generated gas produced in the gasification apparatus using a catalyst to produce a product gas; and a catalyst regenerating apparatus for regenerating the catalyst degraded in the gas reforming apparatus; wherein the gasification apparatus comprises a gasification apparatus having a fluidized bed which uses catalyst particles as at least part of a bed material, and a char combustion apparatus is provided for combusting char (unburned carbon) produced by gasifying the combustibles in the gasification apparatus; and wherein at the same time that the combustibles are gasified to produce a generated gas in the gasification apparatus, the generated gas is reformed by the catalyst particles, and the catalyst particles degraded by reforming the generated gas are delivered to the char combustion apparatus, and heated and regenerated in the char combustion apparatus, and the regenerated catalyst particles are returned to the gasification apparatus.

[0022] As described above, the gasification apparatus comprises a gasification apparatus having a fluidized bed which uses catalyst particles as at least part of a bed material, and at the same time that the combustibles are gasified to produce the generated gas in the gasification apparatus, the generated gas is reformed (tar decomposition) by bringing the generated gas and the catalyst particles as a bed material into contact with each other. Therefore, the generated gas is reformed efficiently, and catalyst particles that function as a desulfurizing agent and a dechlorinating agent can be used, and the generated gas can be desulfurized and dechlorinated. In addition to the effect of claims 3 and 4, gasification of the raw material and reforming of the gas, and combustion of the char and regeneration of the catalyst can be performed in one apparatus. Consequently, a catalyst regenerating apparatus can be eliminated, and the initial cost of the apparatus can be reduced.

[0023] According to the invention defined in claim 7, there is provided a combustible gas reforming apparatus comprising: a gasification apparatus for gasifying combustibles; a gas reforming apparatus for reforming a generated gas produced in the gasification apparatus using a catalyst to produce a product gas; and a catalyst regenerating apparatus for regenerating the catalyst degraded in the gas reforming apparatus; wherein the gasification apparatus comprises a gasification chamber and a combustion chamber each having a fluidized bed which uses catalyst particles as at least part of a bed material, the gasification chamber being constructed to gasify the combustibles to produce a generated gas and the combustion chamber being constructed to combust char (unburned carbon) produced by gasifying the combustibles; and wherein at the same time that the combustibles are gasified to produce a generated gas in the gasification chamber, the generated gas is reformed by the catalyst particles, and the catalyst particles degraded by reforming the generated gas are delivered to the combustion chamber, and heated and regenerated in the combustion chamber, and the regenerated catalyst particles are returned to the gasification chamber.

[0024] As described above, the gasification apparatus comprises a gasification chamber and a combustion chamber each having a fluidized bed which uses catalyst particles as at least part of a bed material, and at the same time that the combustibles are gasified into the generated gas in the gasification chamber, the generated gas is reformed by the catalyst particles, and the degraded catalyst particles are delivered to the combustion chamber, and heated and regenerated in the combustion chamber. Consequently, in addition to the effect of the invention of claim 6, the problem of handling of particles including char from the gasification chamber to the combustion chamber can be solved, and the heat efficiency is improved.

[0025] According to the invention defined in claim 8, there is provided a combustible gas reforming apparatus comprising: a gasification apparatus for gasifying combustibles; and a gas reforming apparatus for reforming a generated gas produced in the gasification apparatus using a catalyst to produce a product gas; wherein the gas reforming apparatus comprises a dust collecting and catalytic reaction apparatus having a dust collecting function to remove dust contained in the generated gas and a gas reforming function to reform the generated gas with the catalyst.

[0026] As described above, inasmuch as the dust collecting and catalytic reaction apparatus having a dust collecting function and a gas reforming function performs dust collecting of the generated gas from the gasification apparatus before the generated gas is reformed (tar decomposition) by the catalyst, the catalyst is prevented from being degraded and from being mixed with a dust. Further, separation of the catalyst is eliminated. In addition, the catalytic reaction apparatus may be of such a type as a reactor having a fixed bed which may possibly be clogged and may not be used in the presence of dust. Furthermore, the arrangement is suitable for preventing the catalyst, which decomposes tar at a low temperature, from being degraded or contaminated.

[0027] According to the invention defined in claim 9, there is provided a combustible gas reforming apparatus according to claim 8, wherein a char combustion apparatus and a catalyst regenerating apparatus are provided; and wherein the catalyst degraded by reforming the generated gas in the dust collecting and catalytic reaction apparatus is delivered to the catalyst regenerating apparatus, char (unburned carbon) produced when the combustibles are gasified to produce the generated gas by the gasification apparatus is delivered to the char combustion apparatus and combusted in the char combustion apparatus, and a combustion exhaust gas from the char combustion apparatus is delivered to the catalyst regenerating apparatus to heat and regenerate the catalyst.

[0028] As described above, since the catalyst degraded by reforming the generated gas is heated and regenerated by the catalyst regenerating apparatus with the heat of the combustion exhaust gas from the char combustion apparatus, in addition to the effect of the invention of claim 8, the catalyst can efficiently be regenerated and heated by the high-temperature heat of combustion of the char without using external energy or combusting part of the generated gas. It is thus possible to increase the yield of the generated gas. The overall amount of consumed energy is reduced, the running cost is low, and an LCA evaluation is high.

[0029] According to the invention defined in claim 10, there is provided a combustible gas reforming apparatus according to claim 8, wherein the gasification apparatus comprises a gasification chamber and a combustion chamber each having a fluidized bed, the gasification chamber being constructed to gasify the combustibles to produce a generated gas and the combustion chamber being constructed to combust char (unburned carbon) produced by gasifying the combustibles; and wherein a catalyst regenerating apparatus is further provided, the catalyst degraded by reforming the generated gas in the dust collecting and catalytic reaction apparatus is delivered to the catalyst regenerating apparatus, and a combustion exhaust gas from the combustion chamber is delivered to the catalyst regenerating apparatus to heat and regenerate the catalyst.

[0030] As described above, since the gasification apparatus comprises a gasification chamber and a combustion chamber each having a fluidized bed, and the catalyst degraded by reforming the generated gas is heated and regenerated by the catalyst regenerating apparatus with the combustion exhaust gas from the combustion chamber, in addition to the effect of the invention of claim 9, the problem of handling of particles including char from the gasification chamber to the combustion chamber can be solved, a heat loss due to a heat radiation is reduced, and the heat efficiency is improved.

[0031] According to the invention defined in claim 11, there is provided a combustible gas reforming apparatus according to claim 8, wherein the gasification apparatus comprises a gasification chamber, a combustion chamber, and a dust collecting and catalyst reaction chamber each having a fluidized bed, the gasification chamber being constructed to gasify the combustibles to produce a generated gas, the combustion chamber being constructed to combust char (unburned carbon) produced by gasifying the combustibles, and the dust collecting and catalyst reaction chamber being constructed to reform the generated gas from the gasification chamber; and wherein a catalyst regenerating apparatus is further provided, the catalyst degraded by reforming the generated gas in the dust collecting and catalyst reaction chamber is delivered to the catalyst regenerating apparatus, a combustion exhaust gas from the combustion chamber is delivered to the catalyst regenerating apparatus to heat and regenerate the catalyst, and the heated and regenerated catalyst is returned to the dust collecting and catalyst reaction chamber.

[0032] As described above, since the gasification apparatus comprises a gasification chamber, a combustion chamber, and a dust collecting and catalyst reaction chamber each having a fluidized bed, in addition to the effect of the invention of claim 10, the problem of handling of particles including char from the dust collecting and catalyst reaction chamber to the combustion chamber can be solved, and the heat efficiency is improved. Because the dust collecting and catalyst reaction chamber is integrally combined with the gasification apparatus, the initial cost of the apparatus is lowered.

[0033] According to the invention defined in claim 12, there is provided a combustible gas reforming apparatus according to claim 8, wherein the gasification apparatus comprises a fluidized-bed furnace having a gasification chamber, a combustion chamber, and a dust collecting and catalyst reaction chamber, the gasification chamber being constructed to gasify the combustibles to produce a generated gas, the combustion chamber being constructed to combust char (unburned carbon) produced by gasifying the combustibles, and the dust collecting and catalyst reaction chamber being constructed to reform the generated gas from the gasification chamber; and wherein the catalyst degraded by reforming the generated gas in the dust collecting and catalyst reaction chamber is delivered to the combustion chamber, heated and regenerated in the combustion chamber, and then the regenerated catalyst is returned to the dust collecting and catalyst reaction chamber.

[0034] As described above, since the catalyst degraded by reforming the generated gas in the dust collecting and catalyst reaction chamber is delivered to the combustion chamber, heated and regenerated in the combustion chamber, and then the regenerated catalyst is returned to the dust collecting and catalyst reaction chamber, in addition to the effect of the invention of claim 11, a catalyst regenerating apparatus can be eliminated. Therefore, the heat efficiency is improved and the initial cost of the apparatus is lowered.

[0035] According to the invention defined in claim 13, there is provided a combustible gas reforming apparatus comprising: a gasification apparatus for gasifying combustibles; a gas reforming apparatus for reforming a generated gas produced in the gasification apparatus using a catalyst to produce a product gas; and a catalyst regenerating apparatus for regenerating the catalyst degraded in the gas reforming apparatus; a catalytic reaction apparatus comprising the gas reforming apparatus and the catalyst regenerating apparatus, and a char combustion apparatus for combusting char (unburned carbon) produced by gasifying the combustibles in the gasification apparatus are provided; wherein the catalytic reaction apparatus is constructed to integrate a gas reforming chamber for reforming the generated gas using catalyst particles and a catalyst regeneration chamber for regenerating the catalyst, the catalyst regeneration chamber being constructed to heat and regenerate the catalyst degraded by reforming the generated gas in the gas reforming chamber, and return the regenerated catalyst to the gas reforming chamber; and wherein the generated gas from the gasification apparatus is delivered to the gas reforming chamber and reformed to produce a product gas, and a combustion exhaust gas from the char combustion apparatus is delivered to the catalyst regenerating apparatus to heat and regenerate the catalyst with the heat of the combustion exhaust gas.

[0036] As described above, since the gas reforming apparatus and the catalyst regenerating apparatus comprise a catalytic reaction apparatus which comprises an integral combination of a gas reforming chamber for reforming the generated gas with catalyst particles and a catalyst regeneration chamber for regenerating the catalyst, the generated gas can efficiently be reformed by fluidization of catalyst particles, and catalyst particles degraded by reforming the generated gas can efficiently be heated and regenerated. A heat loss due to a heat radiation is reduced, and the heat efficiency is improved. In addition, the initial cost of the apparatus is lowered. Therefore, the overall amount of consumed energy is reduced, the running cost is low, and an LCA evaluation is high.

[0037] According to the invention defined in claim 14, there is provided a combustible gas reforming apparatus according to claim 13, wherein the gasification apparatus comprises a gasification chamber and a combustion chamber each having a fluidized bed, the gasification chamber being constructed to gasify the combustibles to produce a generated gas and the combustion chamber being constructed to combust char (unburned carbon) produced by gasifying the combustibles; and wherein the generated gas produced in the gasification chamber is delivered to the gas reforming chamber and reformed in the gas reforming chamber, and a combustion exhaust gas from the combustion chamber is delivered to the catalyst regeneration chamber to heat and regenerate the catalyst with the heat of the combustion exhaust gas.

[0038] As described above, because the gasification apparatus comprises a gasification chamber and a combustion chamber each having a fluidized bed, in addition to the effect of the invention of claim 13, the problem of handling of particles including char from the gasification chamber to the combustion chamber can be solved, and the heat efficiency is improved.

[0039] According to the invention defined in claim 15, there is provided a combustible gas reforming apparatus comprising: a gasification apparatus for gasifying combustibles; a gas reforming apparatus for reforming a generated gas produced in the gasification apparatus using a catalyst to produce a product gas; and a catalyst regenerating apparatus for regenerating the catalyst degraded in the gas reforming apparatus; wherein the gasification apparatus comprises a gasification chamber and a combustion chamber each having a fluidized bed, the gasification chamber being constructed to gasify the combustibles to produce a generated gas and the combustion chamber being constructed to combust char (unburned carbon) produced by gasifying the combustibles; wherein the gas reforming apparatus and the catalyst regenerating apparatus have a gas reforming chamber and a catalyst regeneration chamber each having a fluidized bed which uses catalyst particles as at least part of a bed material, the catalyst regeneration chamber being constructed to heat and regenerate the catalyst degraded by gas reforming in the gas reforming chamber, and return the regenerated catalyst to the gas reforming chamber; wherein the gasification chamber, the combustion chamber, the gas reforming chamber, and the catalyst regeneration chamber are integrated into a single furnace, the generated gas from the gasification apparatus is delivered to the gas reforming chamber and reformed to produce a product gas in the gas reforming chamber, and a combustion exhaust gas from the combustion chamber is delivered to the catalyst regeneration chamber to heat and regenerate the catalyst with the heat of the combustion exhaust gas.

[0040] As described above, because the gasification chamber, the combustion chamber, the gas reforming chamber, and the catalyst regeneration chamber are combined into a single furnace, in addition to the effect of the invention of claim 14, the heat efficiency is further improved. Further, the initial cost of the apparatus is further lowered.

[0041] According to the invention defined in claim 16, there is provided a combustible gas reforming method according to claim 1 or 3, wherein the catalyst regenerating apparatus is supplied with a gas containing one or more of oxygen, steam, and hydrogen as a regenerating gas, and heat of reaction produced when the catalyst is regenerated is used together with process waste heat to heat and regenerate the catalyst particles.

[0042] According to the invention defined in claim 17, there is provided a combustible gas reforming apparatus according to any one of claims 2, 4, and 5 through 15, wherein the catalyst regenerating apparatus is supplied with a gas containing one or more of oxygen, steam, and hydrogen as a regenerating gas, and heat of reaction produced when the catalyst is regenerated is used together with process waste heat to heat and regenerate the catalyst particles.

[0043] According to the inventions defined in claims 16 and 17, a gas containing one or more of oxygen, steam, and hydrogen is supplied as a regenerating gas for regenerating the catalyst, and heat of reaction generated when the catalyst is regenerated and process waste heat are used to heat and regenerate catalyst particles. Since a shortage of the process waste heat can be supplemented with the heat of reaction, the yield of the generated gas can further be improved.

[0044] According to the invention defined in claim 18, there is provided a combustible gas reforming apparatus according to any one of claims 2, 4, and 5 through 17, wherein the gasification apparatus is charged with an absorbent for absorbing chlorine compounds or sulfur compounds when the raw material is gasified.

[0045] As described above, since the gasification apparatus is charged with an absorbent for absorbing chlorine compounds or sulfur compounds, the chlorine compounds and the sulfur compounds can be reduced, and harm to the catalyst is reduced. Since the service life of the catalyst is increased, the running cost of the apparatus is lowered.

BRIEF DESCRIPTION OF DRAWINGS

[0046]
FIG. 1 is a view showing a system construction of an apparatus for carrying out a conventional combustible gasification method which uses a catalyst;

[0047]
FIG. 2 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0048]
FIG. 3 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0049]
FIG. 4 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0050]
FIG. 5 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0051]
FIG. 6 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0052]
FIG. 7 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0053]
FIG. 8 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0054]
FIG. 9 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0055]
FIG. 10 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0056]
FIG. 11 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0057]
FIG. 12 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0058]
FIG. 13 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0059]
FIG. 14 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0060]
FIG. 15 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0061]
FIG. 16 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0062]
FIG. 17 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0063]
FIG. 18 is a view showing an example of a construction of a dust collecting and catalytic reaction apparatus for use in an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0064]
FIG. 19 is a view showing an example of a construction of a dust collecting and catalytic reaction apparatus for use in an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0065]
FIG. 20 is a view showing an example of a construction of a dust collecting and catalytic reaction apparatus for use in an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0066]
FIG. 21 is a view showing an example of a construction of a dust collecting and catalytic reaction apparatus for use in an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0067]
FIG. 22 is a view showing an example of a construction of a dust collecting and catalytic reaction apparatus for use in an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0068]
FIG. 23 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0069]
FIG. 24 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0070]
FIG. 25 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0071]
FIG. 26 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0072]
FIG. 27 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0073]
FIG. 28 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0074]
FIG. 29 is a view showing a construction of a furnace section of the apparatus shown in FIG. 28;

[0075]
FIG. 30 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0076]
FIG. 31 is a view showing a construction of a furnace section of the apparatus shown in FIG. 30;

[0077]
FIG. 32 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0078]
FIG. 33 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0079]
FIG. 34 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention;

[0080]
FIG. 35 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus according to the present invention;

[0081]
FIG. 36 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus according to the present invention;

[0082]
FIG. 37 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus according to the present invention;

[0083]
FIG. 38 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus according to the present invention;

[0084]
FIG. 39 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus according to the present invention;

[0085]
FIG. 40 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus according to the present invention;

[0086]
FIG. 41 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus according to the present invention;

[0087]
FIG. 42 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus according to the present invention;

[0088]
FIG. 43 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus according to the present invention;

[0089]
FIG. 44 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus according to the present invention;

[0090]
FIG. 45 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus according to the present invention;

[0091]
FIG. 46 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus according to the present invention;

[0092]
FIG. 47 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus according to the present invention;

[0093]
FIG. 48 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus according to the present invention;

[0094]
FIG. 49 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus according to the present invention;

[0095]
FIG. 50 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus according to the present invention;

[0096]
FIG. 51 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus according to the present invention;

[0097]
FIG. 52 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus according to the present invention;

[0098]
FIG. 53 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus according to the present invention;

[0099]
FIG. 54 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus according to the present invention;

[0100]
FIG. 55 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus according to the present invention;

[0101]
FIG. 56 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus according to the present invention;

[0102]
FIG. 57 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus according to the present invention;

[0103]
FIG. 58 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus according to the present invention;

[0104]
FIG. 59 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus according to the present invention;

[0105]
FIG. 60 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus according to the present invention;

[0106]
FIG. 61 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus according to the present invention;

[0107]
FIGS. 62A and 62B are views showing an example of a construction of a catalyst regenerating and gas reforming apparatus according to the present invention;

[0108]
FIGS. 63A through 63C are views showing an example of a construction of a catalyst regenerating and gas reforming apparatus according to the present invention;

[0109]
FIG. 64 is a view showing an example of a construction of a gasification apparatus according to the present invention;

[0110]
FIG. 65 is a view showing an example of a construction of a gasification apparatus according to the present invention;

[0111]
FIG. 66 is a view showing an example of a construction of a gasification apparatus according to the present invention;

[0112]
FIG. 67 is a view showing an example of a construction of a gasification apparatus according to the present invention;

[0113]
FIG. 68 is a view showing an example of a construction of a cracking apparatus for use in a gasification apparatus according to the present invention;

[0114]
FIG. 69 is a view showing an example of a construction of a gasification apparatus according to the present invention; and

[0115]
FIG. 70 is a view showing an example of a construction of a gasification apparatus according to the present invention.

BEST MODE FOR CARRYING OUT THE INVENTION

[0116] Embodiments of the present invention will be described below. Reactions (tar decomposition) in a combustible gas reforming apparatus include the following reactions by representing tar component with CnHm:

[0117] {circumflex over (1)} Cracking:

CnHmOk+catalyst→CpHq+H2+C (deposited carbon)+CO

[0118] {circumflex over (2)} Steam reforming:

CnHmOk+H2O+catalyst→CO+H2

[0119] {circumflex over (3)} Carbon dioxide reforming:

CnHmOk+CO2+catalyst→CO+H2

[0120] In the cracking (pyrolysis reaction), pyrolysis occurs on the catalyst, decomposing the tar into low molecular hydrocarbon and carbon monoxide. At the same time, carbon is deposited on the surface of the catalyst. The deposited carbon is one of the causes of deterioration of the catalyst (If the carbon covers the catalyst, then the catalyst is inactivated. The carbon deposited on the catalyst needs to be combusted away in a high-temperature oxidizing atmosphere with a regenerating apparatus). The above reaction is referred to as “cracking”. Industrially, this reaction is equivalent to a reaction for lightening macromolecular hydrocarbons such as normal-pressure residual oil, similar to a tar, in a petroleum refining process. Catalysts for promoting the cracking, such as silica alumina, zeolite, or activated clay are known and in general use.

[0121] In the steam reforming and the carbon dioxide reforming, the tar reacts with steam (H2O) and carbon dioxide (CO2), and is reformed into CO and H2. The reactions between hydrocarbon and H2O and CO2 in the presence of a catalyst are equivalent to a process of manufacturing hydrogen from a natural gas and, in recent years, a process of manufacturing a synthesis gas from macromolecular hydrocarbons such as naphtha, kerosene, etc. Catalysts for promoting the reforming, such as an Ni-based catalyst, etc. are known and in general use.

[0122] The above reactions of the cracking, the steam reforming, and the carbon dioxide reforming can be promoted at a low temperature by using catalysts. These catalysts contribute to any of the above reactions of the cracking, the steam reforming, and the carbon dioxide reforming. For the cracking reaction, however, typical metals (Al, Si, Ca, Mg) and their oxides, or their mixtures should preferably be used as catalysts. Specifically, these catalysts include zeolite (hydrated aluminosilicate), silica alumina (SiO2—Al2O3), activated alumina (Al2O3), activated clay (SiO2—Al2O3), dolomite (CaO, MgO), limestone (CaCO3), calcium oxide (CaO), etc. Among these materials, the materials which have pores that have diameters of about 10 to 150 angstroms and allow the tar to be diffused in catalyst particles are preferred, and the materials having an excellent ability to adsorb macromolecular hydrocarbons are preferred.

[0123] In order to promote the reactions of the steam reforming and the carbon dioxide reforming, it is preferable to use catalysts (e.g., Ni/Al2O3, Ni/CaO.Al2O3, Ru/MgO.Al2O3) which comprise at least one of metals (Rh, Ru, Ni, Pd, Pt, Co, Mo, Ir, Re, Fe, Na, K) or oxides of these metals diffused in and carried on the surface of the above catalysts used as a carrier.

[0124] Of the above catalysts, some are highly active with respect to the reaction of the cracking and some are highly active with respect to the reactions of the steam reforming and the carbon dioxide reforming. By selecting those catalysts suitably, it is possible not only to decompose the tar, but also to change the composition of the reformed gas to adjust the composition of the product gas after gas reforming. If a catalyst that is highly active with respect to the reaction of the cracking is used, then a gas containing a large amount of hydrocarbon such as methane (CH4) or ethylene (C2H2) can be produced. In the reactions of the steam reforming and the carbon dioxide reforming, a mixed gas of H2 and CO is produced. In the reaction of the steam reforming, an H2-rich gas is produced. In the reaction of the carbon dioxide reforming, a CO-rich gas is produced. Therefore, by changing the partial pressures of the reforming gas, it is possible to change the ratio of H2/CO in the product gas.

[0125]
FIG. 2 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention. In FIG. 2, reference numeral 11 represents a gasification apparatus. A raw material A such as coal, biomass, municipal wastes, industrial wastes, RDF, waste plastics, etc. is charged into the gasification apparatus 11, and the raw material A is gasified into a generated gas GA. In a gas reforming apparatus 12 which uses a catalyst (catalyst particles) CA, a tar in the generated gas GA is decomposed to reform the generated gas GA, producing a product gas GB. The catalyst CA which has contributed to the reformation of the generated gas GA in the gas reforming apparatus 12 is turned into a degraded catalyst CA′, which is delivered to a catalyst regenerating apparatus 13. In the catalyst regenerating apparatus 13, the degraded catalyst CA∝ is regenerated by process waste heat TP generated in the gasification process. The regenerated catalyst CA is transferred again to the gas reforming apparatus 12. A temperature optimum for reforming the gas with the catalyst CA is in the range of 800° C. to 1100° C. (preferably 900° C.).

[0126] Since the process waste heat TP is used to regenerate the degraded catalyst CA′ in the catalyst regenerating apparatus 13, the consumption of external energy is suppressed, and the effective heat utilization rate is improved. A reduction in the running cost due to a reduction in the consumption of external energy is achieved, and the evaluation according to LCA is improved.

[0127] The above advantages are obtained when the process waste heat TP is used to regenerate the catalyst in the catalyst regenerating apparatus 13. The heat required to regenerate the catalyst CA is often large in quantity and high at temperature. Most of the heat generated in the process is used to recover steam and preheat the gas to be charged, and hence excess waste heat is low-temperature (low-temperature-level) waste heat which is difficult to be used. If part of the high-temperature heat is used to regenerate the catalyst, then the amount of heat required to recover steam and preheat the gas to be charged becomes insufficient, resulting in a need for an auxiliary fuel. Therefore, the consumption of external energy may be increased. A temperature optimum for regenerating the catalyst CA is in the range from 950° C. to 1100° C. (preferably from 950° C. to 1000° C.).

[0128] For example, the catalyst is generally regenerated at a temperature considerably higher than the reaction temperature for acting as the catalyst. In order to make the gas reformed by the catalyst CA higher than the catalyst reaction temperature, part of the product gas GB has to be combusted or an auxiliary fuel has to be used. If part of the product gas GB is combusted, then the advantages of the catalyst utilization method that a low-temperature gas reforming can be performed, in comparison with a gas reforming involving a high-temperature process, are lost.

[0129]
FIG. 3 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention. Those parts shown in FIG. 3 which are identical or correspond to those shown in FIG. 2 are denoted by identical reference characters. Those parts shown in other figures which are identical or correspond to those shown in FIG. 2 are also denoted by identical reference characters. The apparatus shown in FIG. 3 is constructed to solve the problems which are caused by using the process waste heat TP as the catalyst regenerating heat. The apparatus includes a char combustion apparatus 14 for combusting a char (unburned carbon) CX which is produced when the raw material A is gasified in the gasification apparatus 11 of the apparatus shown in FIG. 2. The char combustion apparatus 14 supplies the heat of a combustion exhaust gas GC which is generated by combustion of the char, as the catalyst regenerating heat, to the catalyst regenerating apparatus 13.

[0130] When the catalyst CA in the gas reforming apparatus 12 reforms the generated gas GA (tar decomposition) from the gasification apparatus 11, the catalytic function is degraded due to the deposition of carbonous material, etc. The catalyst regenerating apparatus 13 heats and regenerates the catalyst CA′ having degraded catalytic function by the combustion exhaust gas GC supplied from the char combustion apparatus 14, and charges the regenerated catalyst CA again into the gas reforming apparatus 12.

[0131] When the raw material A such as coal or ligneous biomass containing a large amount of fixed carbon is gasified in the gasification apparatus 11, a char CX containing a large amount of fixed carbon is generated. Since the char CX has its combustion rate extremely lower than volatile gas, the char CX is accumulated in the gasification apparatus 11. The char CX accumulated in the gasification apparatus 11 often poses operational problems. For example, if the gasification apparatus 11 comprises a fluidized-bed furnace, then the char CX is accumulated on the surface of the fluidized bed because the specific gravity of the char CX is lower than the specific gravity of the bed material. Even when the bed material is withdrawn from the bottom of the furnace for discharging incombustibles, the char CX is not withdrawn, but only the bed material is withdrawn and a char bed is formed in the furnace, thus tending to shut off the gasification apparatus 11.

[0132] Since the char combustion rate and the gas combustion rate are related to each other by char combustion rate≦the gas combustion rate, the gas combustion normally consumes oxygen earlier than the char combustion. Therefore, even if oxygen is supplied to increase the combustion of the char CX in order to suppress the accumulation of char CX, the combustible gas is combusted (the energy of the combustible gas is converted into heat more than necessary). Since the temperature in the furnace is increased by such a degree corresponding to the supplied oxygen, the char combustion efficiency is improved due to the increased temperature, but the increased temperature does not have a large effect on the char combustion rate (but larger effect on increase of gas reactivity).

[0133] By providing the char combustion apparatus 14 separately from the gasification apparatus 11 for removing the char from the gasification apparatus 11 and combusting the removed char, the following advantages can be obtained:

[0134] {circumflex over (1)} The char can be combusted under conditions (combustion temperature, residence time, etc.) suitable for the char combustion independently of the gasification apparatus 11.

[0135] {circumflex over (2)} The gas to be turned into the product gas is not combusted by oxygen which is charged for the purpose of combusting the char.

[0136] {circumflex over (3)} The combustible gas is not diluted by the char combustion gas (a high-calorie gas can be extracted).

[0137] {circumflex over (4)} The combustible gas which has great value as the product gas and the combustion gas which has little value can be used independently of each other.

[0138] {circumflex over (5)} In the case where the raw material A contains a large amount of fixed carbon, like coal or ligneous biomass, if the char CX which is discharged in a large quantity is withdrawn and discarded, then the energy utilization ratio of the fuel is lower than that in complete combustion. When the char CX is combusted by the char combustion apparatus 14 and its heat is used, the energy efficiency of the raw material A is improved.

[0139] If the raw material A such as coal or biomass, which contains a large amount of fixed carbon, is to be gasified, the above problem of the char produced in the gasification apparatus 11 can be solved by combusting the char CX withdrawn from the gasification apparatus 11 with the char combustion apparatus 14, supplying the combustion exhaust gas GC to the catalyst regenerating apparatus 13, and using the heat of the combustion exhaust gas GC as the heat to regenerate the catalyst, thereby making it possible to regenerate the degraded catalyst CA′ without combusting part of the product gas GB or using external energy.

[0140] It is difficult to gasify all the char CX into the product gas GB (because the reaction is complex or the gasification rate is low to cause imbalance between the char supply rate and the gas generation rate, though details are not known). Therefore, a conversion ratio of carbon (how much carbon in the fuel can be converted into a gas) is frequently used as an evaluation standard for the gasification of the raw material A which has a large fixed carbon content. However, the energy of fixed carbon which cannot easily be gasified or is difficult to be gasified can be used by combusting the fixed carbon in the char combustion apparatus 14 even though the fixed carbon is not gasified (if the fixed carbon is not combusted, such condition directly results in an energy loss.

[0141] According to the conventional idea of cogeneration based on gasification, the combustion exhaust gas GC produced by combusting the char CX can also be used by recovering its sensible heat with steam and using the recovered sensible heat for electric power generation. However, if a gasified gas is produced at a relatively low temperature with the catalyst CA, then since high-temperature sensible heat is obtained in a limited portion, heat should be used for regenerating the catalyst. (if the gas is heated with part of the recovered electric energy, then the consumption of external energy is suppressed, but the efficiency is lowered by a conversion loss caused by conversion from heat to electric energy).

[0142]
FIG. 4 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention. The apparatus shown in FIG. 4 differs from the apparatus shown in FIG. 3 in that the apparatus includes a dust collector 15 for removing dust contained in the generated gas GA supplied from the gasification apparatus 11, a sorting apparatus 16 for removing incombustibles I from a mixture of incombustibles I, ash J, and char CX discharged from the gasification apparatus 11, and a dust collector 17 for removing ash J from the combustion exhaust gas GC containing ash J and discharged from the char combustion apparatus 14.

[0143] Since the apparatus for reforming a combustible gas is constructed as described above, the ash J and the char CX are removed from the generated gas GA, containing the ash J and the char CX, discharged from the gasification apparatus 11 by the dust collector 15, and then the generated gas GA is supplied to the gas reforming apparatus 12 and the ash J and the char CX which have been removed is supplied to the char combustion apparatus 14. The sorting apparatus 16 selectively removes incombustibles I from the mixture of the incombustibles I, the ash J, and the char CX discharged from the gasification apparatus 11, and supplies the ash J and the char CX to the char combustion apparatus 14. The dust collector 17 removes ash J from the combustion exhaust gas GC discharged from the char combustion apparatus 14, and supplies the combustion exhaust gas GC to the catalyst regenerating apparatus 13, where the sensible heat of the combustion exhaust gas GC is used as the heat to regenerate the catalyst.

[0144] In the above apparatus for reforming a combustible gas, the char CX discharged from the gasification apparatus 11 having a reducing atmosphere is combusted when the char CX is withdrawn with retaining a high temperature and brought into contact with oxygen. Therefore, in order to withdraw the char CX from the gasification apparatus 11, the following measures should be taken:

[0145] a) The char CX should be withdrawn with retaining a high temperature, while keeping a reducing atmosphere (e.g., nitrogen filling or steam purging).

[0146] b) The char CX should be withdrawn while being cooled (steam purging is needed to prevent the trouble of tar adhesion).

[0147] However, in the case of a), there is the possibility that oxygen leaks in from the exterior for various reasons, i.e., a shortage of the filled nitrogen or purge gas, a sealing failure in the feed path, and a pressure imbalance in the gasification apparatus (furnace). Even in a leakage of a small amount of oxygen, an abrupt temperature increase is caused by local combustion, resulting in an adhesion trouble and a blocking trouble caused by clinker.

[0148] Further, in the case of b), safety is ensured relatively with respect to the combustion of the char CX. However, the tar which is present in the gasification furnace may possibly be accompanied by the char CX, and may possibly be deposited and solidified, thus possibly causing a blocking of the path. Therefore, the path needs to be purged with steam to discharge the tar. The combustion of the discharged char to utilize its heat is not preferable from the standpoint of efficiency because the char has to be reheated after it is cooled.

[0149] Further, the flow rate of the char CX that is transferred is also important. The char CX has to be discharged such that it stays in a certain amount in the furnace. If the material to be gasified produces a large amount of char CX, then the amount of char CX that is transferred is very large, and the feeder to be used is large in scale. The amount of the char that is transferred is expressed as follows: The transferred amount of the char=generated amount of the char÷the concentration of the char in the furnace. If the char CX in the gasification apparatus (furnace) 11 is of the same concentration, then the generated amount of the char and the transferred amount of the char are proportional to each other.

[0150] If the gasification apparatus 1 comprises a fluidized-bed furnace, then it is difficult to selectively discharge the char CX (a certain amount of char can be selectively discharged based on the tendency of the char to stay on the surface layer). In most cases, the char is discharged together with the bed material. Therefore, it is necessary to provide an apparatus for sorting out the discharged bed material and the discharged char CX from each other (by way of centrifugation, sieving, different specific gravities), or to employ a fluidized-bed furnace for the char combustion apparatus 14 and circulate the bed material between the gasification apparatus 1 and the char combustion apparatus 14.

[0151]
FIG. 5 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention. The apparatus shown in FIG. 5 is constructed to solve the above problems of the apparatus shown in FIG. 4. The apparatus shown in FIG. 5 differs from the apparatus shown in FIG. 4 in that the gasification apparatus 11 comprises an integrated-type furnace including a gasification chamber 11-1 having a fluidized bed and a combustion chamber 11-2 having a fluidized bed, and there is provided a sorting apparatus 18 for separating incombustibles I from a mixture of incombustibles I, char CX, and ash J withdrawn from the gasification chamber 11-1 and supplying the char CX and the ash J to the combustion chamber 11-2.

[0152] Because the gasification apparatus 11 comprises the integrated-type furnace having the gasification chamber 11-1 and the combustion chamber 11-2, the gasification apparatus 11 has a function to gasify the raw material A and a function to combust the char. Since the char CX is combusted in the same apparatus in which it is produced, the apparatus shown in FIG. 5 is free of the trouble relating to the feeding of the char CX.

[0153] The interior of the gasification apparatus 11 is divided into a compartment (gasification chamber) for gasifying the raw material A and a compartment (combustion chamber) for combusting the char CX, so that the generated gas GA produced by gasifying the raw material A and the combustion exhaust gas GC produced by combusting the char CX can be taken out independently of each other. For example, the freeboard is divided by a partition plate to separate the compartments completely from each other. The compartments should preferably be isolated from each other not only in the freeboard but also in the furnace bottom to prevent oxygen supplied to the combustion chamber 11-2 for thereby combusting the char CX from leaking into the gasification chamber 11-1.

[0154] As described above, the interior of the gasification apparatus 11 is divided into the gasification chamber 11-1 and the combustion chamber 11-2, and the char CX is fed from the gasification chamber 11-1 to the combustion chamber 11-2 by a feeding medium, which should be a bed material MX in the fluidized bed. The char CX generated in the gasification chamber 11-1 is delivered together with the bed material MX into the combustion chamber 11-2, and the char CX is combusted in the combustion chamber 11-2. The bed material MX that is heated with the combustion heat of the char CX is returned again to the gasification chamber 11-1.

[0155] Since the bed material MX is returned from the combustion chamber 11-2 to the gasification chamber 11-1, part of the heat of the combustion chamber 11-2 is used as a heat source for pyrolysis in the gasification chamber 11-1. In this case, both the compartments in the furnace bottom where the bed material MX is present require a passage for moving the bed material. The presence of the bed material MX and the maintenance of an appropriate fluidizing velocity make it possible to prevent oxygen from leaking from the combustion chamber 11-2 into the gasification chamber 11-1 to a certain extent. In addition, it is desirable that a bed in which the bed material moves be disposed between the gasification chamber 11-1 and the combustion chamber 11-2, like an internal circulating fluidized-bed gasification furnace, or the bed material be returned to the furnace bottom of the gasification chamber 11-1 where the concentration of the raw material is low.

[0156] If the raw material A contains a large amount of incombustibles, then a discharge mechanism (incombustible discharge apparatus, sorting apparatus) is needed for removing incombustibles from the gasification chamber 11-1 as with the conventional gasification apparatus. In FIG. 5, the sorting apparatus 18 is provided for separating incombustibles I from a mixture of incombustibles I, char CX, and ash J discharged from the gasification chamber 11-1 and supplying the char CX and the ash J to the combustion chamber 11-2. For handling the char CX that accompanies the incombustibles I discharged from the gasification chamber 11-1, care should be taken to isolate the char from oxygen and prevent fouling. However, the danger of the trouble is reduced because all the amount of the char corresponding to the amount of char to be generated is not discharged from the gasification chamber 11-1.

[0157] The generated gas GA containing the char CX and the ash J and discharged from the gasification chamber 11-1 is passed through the dust collector 15, which removes the char CX and the ash J. The removed char CX is returned to the combustion chamber 11-2 (for the purpose of combusting the char CX) and to the gasification chamber 11-1 (for the purpose of gasifying the char CX), if necessary (if a large amount of char CX is removed). The gas reforming apparatus 12 can be replenished with the catalyst (catalyst particles) CA, and can be supplied with an oxidizing agent OX (e.g. steam+oxygen) under certain catalyst reaction conditions for achieving higher temperatures.

[0158]
FIG. 32 is a view of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention. The apparatus shown in FIG. 32 is another example of the apparatus shown in FIG. 5, and has a preferred construction for solving the problem which occurs if the char CX generated when the raw material A1 is pyrolyzed is in a small quantity.

[0159] The above problem can be solved by supplying a raw material A1 to a gasification chamber 101 and supplying a raw material A2 to a combustion chamber 102 for thereby making up for a shortage of the quantity of heat given to the bed material in the combustion chamber 102. Specifically, the quantity of heat given to the bed material in the combustion chamber 102 can effectively be used as a heat source for gasifying the raw material A1 in the gasification chamber 101.

[0160] In the present embodiment, the integrated-type gasification furnace 100 is constructed such that the gasification chamber 101 and the combustion chamber 102 are supplied with the raw material A1 and the raw material A2, respectively.

[0161] A burner may be installed in an upper portion of the combustion chamber 102 to combust a combustible gas introduced as the raw material A2. Alternatively, the combustion chamber 102 may be supplied with a combustible gas as the raw material A2.

[0162] In the present embodiment, a generated gas GA generated in the gasification chamber 101 is passed through a dust collector 103, a gas reforming apparatus 104, and a gas temperature reducing and cleaning apparatus 104, and then a product gas GB is produced. On the other hand, a combustion gas GD obtained from the combustion chamber 102 is passed through a waste heat recovery device 107 (e.g., a waste heat boiler), a dust collector 108, and an induced draft fan 109, and then the gas is discharged from a stack 110 into the atmosphere.

[0163] The dust collector 108 may comprise a bag filter or, in particular, an electrostatic precipitator if the concentrations of heavy metals and chlorine components contained in the raw materials A1, A2 are low. If the waste heat recovery device 107 comprises a boiler, then steam produced by the boiler may be used as a gas GE introduced into the gasification chamber 101.

[0164] Further, part of the combustion gas GD is introduced via a branch pipe 120 into the catalyst regenerating apparatus 115 to supply the quantity of heat which is necessary to regenerate the catalyst. The gas, from which the quantity of heat is removed, is returned from the catalyst regenerating apparatus 115 via a branch pipe 121 to a passage 111 of the combustion gas GD.

[0165] The raw material A2 may be the same as the raw material A1 or may be an auxiliary fuel. If the raw materials A1, A2 contain a large amount of incombustibles, then there may be provided not only an incombustible discharge mechanism for discharging incombustibles from the gasification chamber 101, but also an incombustible discharge mechanism for discharging incombustibles from the combustion chamber 102. The incombustibles discharged from the gasification chamber 101 and the combustion chamber 102 may be sorted by a common mechanism or respective separate mechanisms.

[0166]
FIG. 6 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention. The apparatus shown in FIG. 6 differs from the apparatus shown in FIG. 5 in that a bed material of the fluidized bed of the gasification apparatus 11 comprises a mixture of a bed material (sand) MX and a catalyst (catalyst particles) CA; a mixture of char CX, ash J, incombustibles I, a bed material MX, and a catalyst CA′ discharged from the gasification chamber 11-1 or the combustion chamber 11-2 of the gasification apparatus 11 is introduced into the sorting apparatus 18; the incombustibles I are removed by the sorting apparatus 18; the char CX and the ash J are returned to the combustion chamber 11-1; the catalyst CA is returned through a feed passage 19 to the gas reforming apparatus 12; and the catalyst CA′ which has contributed to the gas reforming and has been degraded in the gas reforming apparatus 12 is returned to the combustion chamber 11-2.

[0167] Since the apparatus for carrying out the combustible gas reforming method is constructed as described above, the catalyst CA′ which has been degraded can be heated and regenerated by heat, for example, the combustion heat of the char CX in the combustion chamber 11-2 of the gasification apparatus 11. Therefore, the catalyst regenerating apparatus 13 in the apparatus shown in FIG. 5 can be eliminated. The degraded catalyst CA′ is charged directly into the combustion chamber 11-2 to combust and remove deposited carbon which is one of the causes of the degradation of the catalyst, and hence the catalyst is regenerated. The feed passage 19 may be replenished with the catalyst CA. The mixture of the char CX, the ash J, the incombustibles I, the bed material MX, and the catalyst CA may be discharged from the gasification chamber 11-1 if the incombustibles I are present in a large amount, otherwise may be discharged from either the gasification chamber 11-1 or the combustion chamber 11-2.

[0168]
FIG. 7 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention. The apparatus shown in FIG. 7 differs from the apparatus shown in FIG. 6 in that the combustion exhaust gas GCcontaining the regenerated catalyst CA and the ash J and discharged from the combustion chamber 11-2 of the gasification apparatus 11 is introduced into the dust collector 17, which removes the catalyst CA and the ash J from the combustion exhaust gas GC; the removed catalyst CA and ash J are introduced into a sorting apparatus 20, which selectively removes the ash J; and the remaining catalyst CA is returned via a feed passage 19′ to the gas reforming apparatus 12. The gas reforming apparatus 12 is replenished with the catalyst CA via the feed passage 19′.

[0169]
FIG. 8 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention. The apparatus shown in FIG. 8 differs from the apparatus shown in FIG. 5 in that the catalyst CA regenerated by the catalyst regenerating apparatus 13 is introduced into the gasification chamber 11-1 of the gasification apparatus 11; the raw material A is gasified in the gasification chamber 11-1 and the generated gas GA is reformed (tar decomposition) in the gasification chamber 11-1; a mixture of reformed generated gas GA′, char CX, ash J, and degraded catalyst CA′ which has contributed to the gas reforming is introduced into the dust collector 15, which removes the char CX, the ash J, and the degraded catalyst CA′; and the reformed generated gas GA′ is obtained as the product gas GB.

[0170] The char CX, the ash J, and the degraded catalyst CA′ which have been removed by the dust collector 15 are introduced into the sorting apparatus 20, which sorts the char CX and the ash J, and the sorted char CX and ash J are delivered to the combustion chamber 11-2, and the remaining degraded catalyst CA′ is delivered to the catalyst regenerating apparatus 13. The catalyst CA heated and regenerated by the catalyst regenerating apparatus 13 is fed to the gasification apparatus 11-1 as described above. A feed passage for feeding the catalyst CA to the gasification chamber 11-1 can be replenished with the catalyst CA.

[0171]
FIG. 9 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention. The apparatus shown in FIG. 9 differs from the apparatus shown in FIG. 8 in that the char CX and the ash J removed from the reformed generated gas GA′ by the dust collector 15 are returned to the combustion chamber 11-2 of the gasification apparatus 11; and a mixture of the char CX, the ash J, the incombustibles I, and the degraded catalyst CA′ discharged from the gasification chamber 11-1 of the gasification apparatus 11 is introduced into the sorting apparatus 18, which selectively discharges the incombustibles I; and the char CX and the ash J are returned to the combustion chamber 11-2, and the degraded catalyst CA′ is transferred to the catalyst regenerating apparatus 13. The gasification chamber 11-1 can be replenished with the catalyst CA.

[0172]
FIG. 10 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention. The apparatus shown in FIG. 10 includes a gasification apparatus comprising a fluidized-bed furnace which employs catalyst particles as a bed material. Reference numeral 21 represents a gasification apparatus having a fluidized-bed gasification furnace which uses the catalyst (catalyst particles) CA as a bed material. The gasification apparatus 21 gasifies the raw material A and at the same time reforms the gas (tar decomposition). The reformed generated gas GA′ is passed through a dust collector 22, which removes the char CX, the ash J, and the degraded catalyst (catalyst particles used as the bed material and degraded) CA′, producing the product gas GB. The char CX, the ash J, and the catalyst CA′ removed by the dust collector 22 are delivered to a char combustion apparatus 24, which combusts the char CX.

[0173] The mixture of the incombustibles I, the char CX, the ash J, and the catalyst CA′ removed from the gasification apparatus 21 is delivered to a sorting apparatus 23, which selectively removes and discharges the incombustibles I by way of sieving, magnetic separation, and separation based on different specific gravities, etc. The remaining char CX, the ash J, and the catalyst CA′ are supplied to the char combustion apparatus 24. In the char combustion apparatus 24, the supplied char CX is combusted together with the char CX supplied from the dust collector 22. The degraded catalyst CA′ is heated and regenerated into the catalyst CA by the sensible heat produced upon combustion of the char. The catalyst CA is removed from the furnace bottom of the char combustion apparatus 24, and delivered again to the gasification apparatus 21 for use as the bed material and the catalyst again.

[0174] If the catalyst particles from the char combustion apparatus 24 are broken into smaller particles or particles of the catalyst CA are originally small, then since the catalyst particles tend to be scattered in a large quantity with the combustion exhaust gas GC, the catalyst particles are delivered to the dust collector 25, which traps the catalyst CA and the ash J and thus removes them from the combustion exhaust gas GC. The trapped and removed catalyst CA and the ash J are fed to a sorting apparatus 26, which separates the catalyst CA and ash J from each other. The ash J is selectively removed and discharged from the sorting apparatus 26, and the catalyst CA is delivered to the gasification apparatus 21. In the gasification apparatus 21, the catalyst CA is used as the bed material and the catalyst as with the catalyst CA supplied from the char combustion apparatus 24. The sorting apparatus 26 sorts out the catalyst CA and the ash J from each other by way of sorting based on different specific gravities or centrifugation, depending on the state of the particles of the catalyst CA.

[0175] With the apparatus shown in FIG. 10, the handling of the particles including the char CX is required, and oxygen blocking is required. Since the tar is decomposed by the catalyst at the same time that the raw material is gasified, the trouble of tar adhesion is less liable to occur even if the feed passage is cooled, and the particles including the char CX can be cooled and fed. However, cooling the catalyst CA and returning the catalyst CA to the gasification apparatus 21 leads to a reduction in the thermal efficiency.

[0176]
FIG. 11 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention. The apparatus shown in FIG. 11 is constructed to solve the above problems of the apparatus shown in FIG. 10. The apparatus shown in FIG. 11 is different from the apparatus shown in FIG. 10 in that the gasification apparatus 21 comprises an integrated-type furnace including a gasification chamber 21-1 having a fluidized bed and a combustion chamber 21-2 having a fluidized bed. At the same time that the raw material A is gasified in the gasification chamber 21-1, the generated gas GA is brought into contact with the catalyst CA serving as the bed material and is reformed. The reformed generated gas GA′ is passed through the dust collector 22, which removes the char CX, the ash J, and the catalyst (degraded catalyst) CA′ contained therein, producing the product gas GB. The char CX, the ash J, and the catalyst CA′ removed by the dust collector 22 are delivered into the combustion chamber 21-1 and combusted therein.

[0177] The catalyst (bed material) CA′ containing the char CX and discharged from the gasification chamber 21-1 is introduced into the combustion chamber 21-2, and the catalyst CA′ is heated and regenerated by the combustion heat of the char CX in the combustion chamber 21-2. The regenerated catalyst CA is delivered again into the gasification chamber 21-1. Further, the mixture of the incombustibles I, the char CX, the ash J, and the catalyst CA′ removed from the gasification chamber 21-1 is delivered to the sorting apparatus 23, which selectively removes and discharges the incombustibles I. The remaining char CX, ash J, and catalyst CA′ are sent to the combustion chamber 21-2, and the char CX is combusted to contribute to the heating and regeneration of the degraded catalyst CA′ in the combustion chamber 21-2. The exhaust gas GC containing the ash J and the char CX discharged from the combustion chamber 21-2 is sent to the dust collector 25, which removes and discharges the ash J and the catalyst CA. The removed ash J and catalyst CA are delivered to the sorting apparatus 26, which separates the ash J and the catalyst CA from each other. The separated catalyst CA is delivered again into the gasification chamber 21-1.

[0178] The particulate catalyst CA as the bed material is directly moved in the same fluidized-bed furnace. As with the internal circulating fluidized-bed gasification furnace, the bed material (catalyst CA) is moved based on the difference between the fluidizing velocities of the bed material in the gasification chamber 21-1 and the combustion chamber 21-2. As with the apparatus shown in FIG. 10, if the catalyst CA can easily be scattered because it tends to be broken into smaller particles or it is originally in the form of small particles, then the catalyst CA should be sorted out by the sorting apparatus 26 from the mixture of the ash J and the catalyst CA trapped by the dust collector 25, and returned to the gasification chamber 21-1. Further, the gasification chamber 21-1 and the combustion chamber 21-2 should be isolated from each other, and a means for preventing oxygen from leaking from the combustion chamber 21-2 into the gasification chamber 21-1 should be provided, as with the above embodiments.

[0179] If the bed material for use in the fluidized-bed furnace of the gasification apparatus 21 comprises catalyst particles (CaO, Al2O3Ni, FeSiO2, MgSiO2, etc.) for decomposing tar, then the gasification of the raw material A and the tar decomposition based on the catalytic action can simultaneously be performed. Since CaO or the like functions as a desulfurizing agent and a dechlorinating agent, desulfurization and dechlorination can also be carried out simultaneously.

[0180]
FIG. 12 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention. In the apparatus shown in FIG. 12, a raw material A such as biomass, municipal wastes, industrial wastes, RDF, waste plastics, etc. is gasified in a gasification apparatus 31, and dust collecting of a generated gas GA and reformation of the generated gas are performed by a dust collecting and catalytic reaction apparatus 32, thus producing a product gas GB.

[0181] The generated gas GA discharged from the gasification apparatus 31 contains tar, dust, and char, as described above, which need to be removed. If the gas has been reformed (tar decomposition), then the dust and char can be removed from the gas by a wet-type gas cleaning. Because the gas before decomposition of tar causes the problem of tar deposition upon cooling of the gas, the tar has to be decomposed before the gas is cooled. The dust collecting of the gas should preferably be performed in a stage prior to the catalytic reaction apparatus in order to prevent the catalyst which decomposes the tar at a low temperature from being degraded and contaminated.

[0182] A ceramic filter has been used as a high-temperature dust collector for use in a temperature range for gasifying the raw material A. When dust collecting is performed in such a state that the tar is not decomposed, no problem arises when the apparatus operates at a high temperature. However, when the apparatus is stopped, oxygen and tar may react with each other, causing the damage due to local high temperatures or the trouble of clogging due to tar deposition.

[0183] In order to solve the above problems, the system shown in FIG. 12 employs the dust collecting and catalytic reaction apparatus 32 disposed in a stage subsequent to the gasification apparatus 31. Specifically, the dust collecting and catalytic reaction apparatus 32 includes a filter section of a dust collecting apparatus which carries a catalyst or a particulate filter filled with catalyst particles. When the generated gas GA passes through the filter which has a catalytic function, the dust collecting of the generated gas GA is performed by the filter, and the decomposition of the tar is accelerated by a catalytic reaction.

[0184]
FIG. 13 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention. The apparatus shown in FIG. 13 employs an arrangement which is a development of the apparatus shown in FIG. 12. As shown in FIG. 13, the degraded catalyst CA′ which has contributed to gas reforming (tar decomposition) in the dust collecting and catalytic reaction apparatus 32 is removed from the dust collecting and catalytic reaction apparatus 32, and delivered to a catalyst regenerating apparatus 33, which regenerates the degraded catalyst CA′. The regenerated catalyst CA is supplied again to the dust collecting and catalytic reaction apparatus 32.

[0185] A mixture of incombustibles I, char CX, and ash J removed from the gasification apparatus 31 is sent to a sorting apparatus 34, which selectively removes the incombustibles I, and the remaining char CX and ash J are fed to a char combustion apparatus 35 in which the char CX is combusted. A combustion exhaust gas GC containing the ash J is delivered from the char combustion apparatus 35 to a dust collector 36, which removes the ash J, and the remaining combustion exhaust gas GC is delivered from the dust collector 36 to the catalyst regenerating apparatus 33. The degraded catalyst CA′ is heated and regenerated with the sensible heat of the combustion exhaust gas GC by the catalyst regenerating apparatus 33. The degraded catalyst CA′ which has contributed to gas reforming (tar decomposition) in the dust collecting and catalytic reaction apparatus 32 may be charged into the catalyst regenerating apparatus 33, and the heated and regenerated catalyst CA may be sorted and returned to the dust collecting and catalytic reaction apparatus 32.

[0186]
FIG. 14 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention, the apparatus being developed from the apparatus shown in FIG. 9. The apparatus shown in FIG. 14 is different from the apparatus shown in FIG. 9 in that a gasification apparatus 31 comprises an integrated-type furnace which includes a gasification chamber 31-1 having a fluidized bed and a combustion chamber 31-2 having a fluidized bed. Because the gasification apparatus 31 comprises the integrated-type furnace having the gasification chamber 31-1 for gasifying the raw material A and the combustion chamber 31-2 for combusting the char, the gasification apparatus 31 has a function to gasify the raw material A and a function to combust the char.

[0187] For example, the freeboard is divided by a partition plate to separate the compartments completely from each other, so that the gasification chamber 31-1 and the combustion chamber 31-2 in the gasification apparatus 31 can take out the generated gas GA produced by gasifying the raw material A and the combustion exhaust gas GC produced by combusting the char CX, independently of each other. The compartments should preferably be isolated from each other not only in the freeboard but also in the furnace bottom to prevent oxygen sufficiently supplied to the combustion chamber 31-2 for combusting the char CX from leaking into the gasification chamber 31-1.

[0188] As described above, the interior of the gasification apparatus 31 is divided into the gasification chamber 31-1 and the combustion chamber 31-2, and the char CX is transferred from the gasification chamber 31-1 to the combustion chamber 31-2 by a bed material MX in the fluidized bed. Specifically, the char CX generated in the gasification chamber 31-1 is delivered together with the bed material MX into the combustion chamber 31-2, and the char CX is combusted in the combustion chamber 31-2, and then the bed material MX that is heated with the combustion heat of the char CX is returned to the gasification chamber 31-1.

[0189] Since the bed material MX is returned from the combustion chamber 31-2 to the gasification chamber 31-1, part of the heat of the combustion chamber 31-2 is used as a heat source for pyrolysis in the gasification chamber 31-1. In this case, the compartments in the furnace bottom where the bed material MX is present require a passage for moving the bed material MX. The presence of the bed material MX and the maintenance of an appropriate fluidizing velocity make it possible to prevent oxygen from leaking from the combustion chamber 31-2 into the gasification chamber 31-1 to a certain extent. In addition, it is desirable that a bed in which the bed material moves be disposed between the gasification chamber 31-1 and the combustion chamber 31-2, like the internal circulating fluidized-bed gasification furnace, or the bed material MX be returned to the furnace bottom of the gasification chamber 31-1 where the concentration of the raw material is low.

[0190] If the raw material A contains a large amount of incombustibles I, then an incombustible discharge mechanism (incombustible discharge apparatus, sorting apparatus) is needed for removing the incombustibles I from the gasification chamber 31-1 as with the conventional gasification apparatus. In FIG. 14, a sorting apparatus 34 is provided for separating the incombustibles I from a mixture of the incombustibles I, the char CX, and the ash J removed from the gasification chamber 31-1 and supplying the char CX and the ash J to the combustion chamber 31-2. For handling the char CX that accompanies the incombustibles I removed from the gasification chamber 31-1, care should be taken to intercept oxygen and prevent a blocking. However, the danger of the trouble is reduced because all the amount of char corresponding to the amount of char to be generated is not removed from the gasification chamber 31-1 unlike the conventional process.

[0191] The char CX removed by a dust collecting and catalytic reaction apparatus 32 is returned to the combustion chamber 31-2 (for the purpose of combustion) or to the gasification chamber 31-1 (for the purpose of gasification), if necessary (if the amount of char CX is large). In the above example, a catalyst CA′ degraded in the dust collecting and catalytic reaction apparatus 32 is heated and regenerated by a catalyst regenerating apparatus 33, and returned again to the dust collecting and catalytic reaction apparatus 32. The combustion chamber 31-2 may be used to regenerate the catalyst. That is, the degraded catalyst CA′ which has contributed to gas reforming (tar decomposition) in the dust collecting and catalytic reaction apparatus 32 may be charged into the combustion chamber 31-2, and the heated and regenerated catalyst CA′ may be selected and returned to the dust collecting and catalytic reaction apparatus 32.

[0192]
FIG. 15 is a view of an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention, the apparatus being developed from the apparatus shown in FIG. 13. The apparatus shown in FIG. 15 includes a gasification, combustion, dust collecting and reforming apparatus 40 for performing, in a single fluidized-bed furnace, the gasification function of the gasification apparatus 31 shown in FIG. 13, the char combustion function of the char combustion apparatus 35 shown in FIG. 13, and the dust collecting and reforming function of the dust collecting and catalytic reaction apparatus 32. Specifically, the gasification, combustion, dust collecting and reforming apparatus 40 comprises a gasification chamber 40-1 for gasifying the raw material A, a combustion chamber 40-2 for combusting the char CX, and a dust collecting and catalyst reaction chamber 40-3 for dust collecting and reforming (decomposing tar) the generated gas GA.

[0193] As shown in FIG. 13, if the dust collecting and catalytic reaction apparatus 32 is provided and employs a particulate filter comprising catalyst particles, then a fixed bed (packed bed) may be used. With respect to the handling of the catalyst particles, the handling of the catalyst particles is facilitated by using the fluidized bed as shown in FIG. 13.

[0194] For heating and regenerating the catalyst particles of a degraded filter for reuse, if the degraded catalyst particles are regenerated with the heat of combustion of the char CX and the regenerated catalyst particles are supplied to the filter, then the handling of the catalyst particles is needed in many situations, e.g., when the catalyst particles are removed from the filter and supplied to the regenerating apparatus, and when the regenerated catalyst particles are supplied to the filter. Unlike the method of removing the catalyst particles with batch processing in the fixed bed, using the gasification apparatus 31 and the gasification-combustion-dust collecting-reforming apparatus 40 which utilize the fluidized-bed (moving bed) technology as shown in FIGS. 14 and 15 makes it possible to continuously remove and supply the catalyst (catalyst particles) CA.

[0195] In the catalyst regenerating apparatus 33, the fluidized bed is effective to increase the ratio of contact between the combustion exhaust gas GC serving as a heat source and the catalyst CA, and makes it easier to remove the regenerated catalyst CA from the catalyst regenerating apparatus 33 than in the case where the combustion exhaust gas GC is brought into contact with the catalyst CA in the packed bed.

[0196] With a cyclone-type dust collector or a centrifugal-separation dust collector, after the catalyst particles are introduced to reform the combustible gas in a stage prior to the dust collector, the catalyst CA is trapped together with the char CX and the dust in the generated gas GA, separated from the generated gas GA, and delivered to the char combustion chamber (catalyst regeneration chamber). In this manner, the gas can simultaneously be dedusted and reformed (tar decomposition).

[0197]
FIG. 16 shows an example of a construction wherein the catalyst is regenerated by a combustion chamber 31-2, rather than being regenerated by the catalyst regenerating apparatus 33 in FIG. 14. As shown in FIG. 16, the gasification apparatus 31 has a fluidized-bed furnace with a fluidized bed 31a, and the fluidized-bed furnace is divided into a gasification chamber 31-1 and a combustion chamber 31-2 by a partition wall 31b. A region of the fluidized bed 31a beneath the lower end of the partition wall 31b serves as a passage for moving the bed material therethrough. The dust collecting and catalytic reaction apparatus 32 has a filter 32a, and a catalyst CA is charged on the filter 32a.

[0198] When a generated gas GA containing char CX and ash J from the gasification chamber 31-1 is supplied to a region below the filter 32a of the dust collecting and catalytic reaction apparatus 32, the char CX and the ash J are trapped and removed by the filter 32a, and the generated gas GA is injected from a distributor nozzle 32c into a fixed bed (packed bed) 32b of the catalyst CA and reformed (tar decomposition) while passing through the fixed bed 32b of the catalyst CA, thus producing a product gas GB. The char CX and the ash J which have been trapped and removed by the filter 32a are supplied, if necessary, to the combustion chamber 31-2 and the gasification chamber 31-1.

[0199] The mixture of the incombustibles I, the ash J, the char CX, and the catalyst CA serving as a bed material, which is removed from the fluidized bed 31a in the gasification chamber 31-1, is supplied to the sorting apparatus 34. The incombustibles I are selectively removed from the sorting apparatus 34, and the ash J, the catalyst CA, and the char CX which remain in the sorting apparatus 34 are returned to the combustion chamber 31-2. The degraded catalyst CA′ (whose catalytic function has been lowered) which has contributed to the reforming of the generated gas GA in the dust collecting and catalytic reaction apparatus 32 is delivered to the combustion chamber 31-2. In the combustion chamber 31-2, the degraded catalyst CA′ is heated and regenerated into a regenerated catalyst CA that is returned to the dust collecting and catalytic reaction apparatus 32. The catalyst CA which has been heated and regenerated in the combustion chamber 31-2 is delivered to the gasification chamber 31-1. A combustion exhaust gas GC from the combustion chamber 31-2 passes through a heat recovery apparatus 37, and hence heat recovery is performed. Thereafter, the combustion exhaust gas GC passes through a dust collector 38, which removes dust from the combustion exhaust gas GC, and is then discharged from the dust collector 38.

[0200]
FIG. 17 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention. The system construction shown in FIG. 17 performs the gasification function, the catalyst regenerating function, the dust collecting function, and the gas reforming function illustrated in FIG. 11 in a single fluidized-bed furnace. As shown in FIG. 17, a gasification-combustion-dust collecting-reforming apparatus 40 includes a fluidized-bed furnace which has a fluidized bed 40a and is divided into a gasification chamber 40-1, a combustion chamber 40-2, and a dust collecting and catalyst reaction chamber 40-3 by partition walls 40b, 40c. Regions of the fluidized bed 40a beneath the lower ends of the partition walls 40b, 40c serve as passages for moving the degraded catalyst CA′ as a bed material therethrough.

[0201] A dust collecting chamber 41 is disposed below the dust collecting and catalyst reaction chamber 40-3. A filter 41a is provided in the dust collecting chamber 41. A generated gas CA containing char CX and ash J and produced by gasification of a raw material A in the gasification chamber 40-1, is introduced into a region below the filter 41a of the dust collecting chamber 41. The char CX and the ash J are trapped by the filter 41a, whereas the remaining generated gas GA is injected through distributor nozzles 41b into the fluidized bed 40a and reformed (tar decomposition) by the catalyst CA as a bed material of the fluidized bed 40a, thus producing a product gas GB that is discharged from the dust collecting and catalytic reaction chamber 40-3. Air L, serving as a fluidizing gas and an oxidizing agent, is usually introduced into the bottom of the fluidized bed 40a.

[0202] The degraded catalyst CA′ which has contributed to the reforming of the generated gas GA (tar decomposition) in the dust collecting and catalyst reaction chamber 40-3 is delivered to the combustion chamber 40-2. In the combustion chamber 40-2, the degraded catalyst CA′ is heated and regenerated, and the regenerated catalyst is returned through a feed passage 40d to the dust collecting and catalyst reaction chamber 40-3. A combustion exhaust gas GC from the combustion chamber 40-2 passes through a heat recovery apparatus 37, and hence heat recovery is performed. Thereafter, the combustion exhaust gas GC passes through the dust collector 38, which removes dust from the combustion exhaust gas GC, and is then discharged from the dust collector 38. The catalyst which has heated and regenerated in the combustion chamber 40-2 is returned through a feed passage 40e to the gasification chamber 40-1.

[0203]
FIG. 18 is a view showing an example of a construction of the dust collecting and catalytic reaction apparatus 32. As shown in FIG. 18, the dust collecting and catalytic reaction apparatus 32 has a filter 32a housed therein. A generated gas GA containing ash J and char CX is introduced from a gas inlet 32-1 into the filter 32a, and the ash J and the char CX are separated from the generated gas GA by the filter 32a. The generated gas GA from which the ash J and the char CX have been removed by the filter 32a is reformed (tar decomposition) while passing through the packed bed 32b of the catalyst CA formed on the filter 32a. The reformed gas is then discharged as a product gas GB from a gas outlet 32-2. The filter 32a comprises a ceramic filter or a metal filter. The ash J and the char CX which have been separated are discharged from an outlet 32-3.

[0204] The dust collecting and catalytic reaction apparatus 32 may be constructed such that as shown in FIG. 19, a packed bed 32c which is filled with sand or ceramic particles as a filler OX, instead of a filter, is provided, and a generated gas GA containing ash J and char CX is introduced from the gas inlet 32-1 into the dust collecting and catalytic reaction apparatus 32, and then the ash J and the char CX are separated from the generated gas GA by the packed bed 32c. In the packed bed 32c, the filler OX moves by flowing-down or the like. When the generated gas GA containing the ash J and the char CX passes through the packed bed 32c, the particles of the filler OX in the packed bed 32c contact and trap the ash J and the char CX, thus separating the ash J and the char CX from the generated gas GA. The generated gas GA which has passed through the packed bed 32c is reformed (tar decomposition) while passing through a packed bed 32b of the catalyst CA that is disposed in a flow passage from the packed bed 32c to the gas outlet 32-2. The reformed gas is discharged as a product gas GB from the gas outlet 32-2. Since the catalyst CA is used in the form of a mixture of the catalyst CA and the filler OX, the filler OX may be replaced in its entirety with the catalyst CA.

[0205] The filler OX, the ash J, and the char CX which are discharged from the outlet 32-3 are classified by a gravity separator based on the different specific gravities of the filler OX, the ash J, and the char CX. The classified filler OX is returned to the packed bed 32c of the dust collecting and catalytic reaction apparatus 32. The ash J is recovered after it is cooled. The filler OX, the ash J, and the char CX are classified in a reducing atmosphere.

[0206] As shown in FIG. 20, the dust collecting and catalytic reaction apparatus 32 may comprise a cyclone-type centrifugal separator for separating, under the centrifugal forces of swirling flows, ash J and char CX from a generated gas GA which contains the ash J and the char CX and is introduced from the gas inlet 32-1. A catalyst (catalyst particles) CA is introduced into the generated gas GA within the dust collecting and catalytic reaction apparatus 32 or near the gas inlet 32-1 through an apparatus, such as a lock hopper 42 or the like, which isolates the atmosphere of the generated gas GA and the external atmosphere from each other, whereby tar contained in the generated gas GA is decomposed by the catalyst CA due to a mixing and stirring action of the swirling flows. In the dust collecting and catalytic reaction apparatus 32, after decomposition of the tar, the ash J, the char CX, and the degraded catalyst CA′ are separated from the generated gas GA, and discharged from the outlet 32-3. After decomposition of the tar, the generated gas GA is discharged as a product gas GB from the gas outlet 32-2.

[0207] The dust collecting and catalytic reaction apparatus 32 may be constructed as shown in FIG. 21 such that the filter 32a is housed within the apparatus; a generated gas GA containing ash J and char CX is introduced from the gas inlet 32-1 into the dust collecting and catalytic reaction apparatus 32; and then the generated gas GA is passed through the filter 32a to trap and separate the ash J and the char CX from the generated gas GA, and the separated ash J and char CX are discharged from the outlet 32-3.

[0208] Tar contained in the generated gas GA is decomposed by the catalyst CA that is filled in a flow passage from the filter 32a to the gas outlet 32-2, and the generated gas GA that has been reformed is discharged as a product gas GB from the gas outlet 32-2. The filter 32a comprises a ceramic filter or a metal filter.

[0209] After the catalyst CA is used to decompose the tar, the catalyst CA is degraded. In order to regenerate the catalyst CA, a distribution means such as distributor nozzles 32b or the like are disposed above the filter 32a. The generated gas GA is ejected through the distribution means to fluidize and move the catalyst CA, thereby discharging the degraded catalyst CA′ from a catalyst outlet 32-4. The filter 32a in the dust collecting and catalytic reaction apparatus 32 should preferably have a slanted surface which is progressively lower toward the catalytic outlet 32-4 for effectively discharging the degraded catalyst CA′.

[0210]
FIG. 22 is a view showing an example of another construction of the dust collecting and catalytic reaction apparatus 32. As shown in FIG. 22, the dust collecting and catalytic reaction apparatus 32 has a packed bed 32c filled with sand or ceramic particles as a filler OX, instead of a filter to separate the ash J and char CX from the generated gas GA. In the packed bed 32c, the filler OX moves by flowing-down or the like. A generated gas GA containing ash J and char CX is introduced from the gas inlet 32-1 into the dust collecting and catalytic reaction apparatus 32. When the generated gas GA containing the ash J and the char CX passes through the packed bed 32c, the ash J and the char CX are contacted and trapped by the particles of the filler OX of the packed bed 32c, and are thus separated from the generated gas GA. The ash J and the char CX that have been separated by the packed bed 32c are discharged from the outlet 32-3 to the outside.

[0211] The dust collecting and catalytic reaction apparatus 32 also has a catalyst packed bed 32d filled with a regenerated catalyst CA. In the catalyst packed bed 32d, the catalyst CA moves by flowing-down or the like as with the packed bed 32c. When the generated gas GA passes through the catalyst packed bed 32d, the catalyst CA decomposes tar contained in the generated gas GA, and the degraded catalyst CA′ is discharged from a catalyst outlet 32-5.

[0212] In the dust collecting and catalytic reaction apparatus 32 constructed as shown in FIG. 22, the catalyst CA may be in the form of particles as with the filler OX and mixed with the filler OX, or the filler OX may be replaced in its entirety with the catalyst CA. In this case, the ash J and the char CX which have been separated by the packed bed 32c are classified by a gravity separator based on the different specific gravities of the filler OX (the catalyst CA), the ash J, and the char CX.

[0213] In the case where the catalyst CA is in the form of particles as with the filler OX and mixed with the filler OX, or the filler OX is replaced in its entirety with the catalyst CA, if the temperature in the dust collecting and catalytic reaction apparatus 32 is in a high temperature range from 900° C. to 1000° C., then since salts are volatilized and do not remain in the ash J, the ash J and the char CX which have been separated by the packed bed 32c can be supplied together with the filler OX and the catalyst CA to the char combustion apparatus or the combustion chamber.

[0214]
FIG. 23 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention. The apparatus shown in FIG. 23 has a gasification apparatus 43 comprising a fluidized-bed furnace which is divided into a gasification chamber 43-1 and a combustion chamber 43-2 by a partition wall 43a. A bed material (sand) MX, a degraded catalyst CA′, and char CX move from the gasification chamber 43-1 in a reducing atmosphere into the combustion chamber 43-2 in an oxidizing atmosphere. In the combustion chamber 43-2, the char CX is combusted, and the degraded catalyst CA′ is heated and regenerated into the catalyst CA. The regenerated catalyst CA moves again into the gasification chamber 43-1, and a combustion exhaust gas GC is discharged.

[0215] A fluidized bed 43-1a in the gasification chamber 43-1 contains the bed material (sand) MX and the catalyst CA, and the raw material A is gasified and simultaneously reformed (tar decomposition) by the catalyst CA. The reformed generated gas GA is introduced into a dust collecting and catalytic reaction apparatus 32 which comprises a cyclone-type centrifugal separator that is of essentially the same structure as the cyclone-type centrifugal separator shown in FIG. 20. A mixture of incombustibles I, the degraded catalyst CA′ including unreacted components, the bed material MX and the ash J, which is removed from the fluidized bed 43-1a in the gasification chamber 43-1, is delivered to the sorting apparatus 34, and the incombustibles I are selectively separated out by the sorting apparatus 34, and the catalyst CA′, the bed material MX, and the ash J which remain in the sorting apparatus 34 are supplied to the dust collecting and catalytic reaction apparatus 32.

[0216] In the dust collecting and catalytic reaction apparatus 32, as with the arrangement shown in FIG. 20, the generated gas GA is further reformed by a gas-phase mixture of the generated gas GA and the catalyst CA, thus producing a product gas GB. The catalyst CA′, the bed material MX, and the ash J from the dust collecting and catalytic reaction apparatus 32 are returned to the combustion chamber 43-2 of the gasification apparatus 43.

[0217]
FIG. 24 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention. The apparatus shown in FIG. 24 has a gasification apparatus 31 which is of substantially the same structure as the gasification apparatus 31 shown in FIG. 12 and a dust collecting and catalytic reaction apparatus 32 which is of substantially the same structure as the dust collecting and catalytic reaction apparatus 32 shown in FIG. 20. A mixture of incombustibles I, catalyst CA′ and ash J, which is removed from the fluidized bed 31a in the gasification chamber 31-1, is delivered to the sorting apparatus 34, and the incombustibles I are selectively removed by the sorting apparatus 34, and the catalyst CA′ and the ash J which remain in the sorting apparatus 34 are returned to the gasification chamber 31-1. In the gasification chamber 31-1, the raw material A is gasified and the generated gas GA is reformed by the catalyst CA. The mixture of the generated gas GA, the ash J, and the char CX from the gasification chamber 31-1 is delivered to the dust collecting and catalytic reaction apparatus 32.

[0218] In the dust collecting and catalytic reaction apparatus 32, as with the arrangement shown in FIG. 20, the generated gas G′A is further reformed by a gas-phase mixture of the generated gas GA and the catalyst CA, thus producing a product gas GB. The catalyst CA′, the char CX, and the ash J from the dust collecting and catalytic reaction apparatus 32 are returned to the combustion chamber 31-2 of the gasification apparatus 31.

[0219]
FIG. 25 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention. As shown in FIG. 25, the apparatus employs a fluidized-bed catalytic reaction apparatus 56 as a catalytic reaction and catalyst regenerating apparatus. The fluidized-bed catalytic reaction apparatus 56 uses catalyst particles as a bed material, and has a furnace divided into a reaction chamber 56-1 where the catalyst CA reacts and a regeneration chamber 56-2 where the degraded catalyst CA′ is regenerated. The reaction chamber 56-1 is in a reducing atmosphere, and the regeneration chamber 56-2 is in an oxidizing atmosphere. The reaction chamber 56-1 and the regeneration chamber 56-2 are divided from each other by a partition plate (not shown) to allow gases to pass independently through the reaction chamber 56-1 and the regeneration chamber 56-2, respectively. The divided compartments are designed depending on the amount of a generated gas GA to be processed, thereby keeping an appropriate fluidizing velocity between the compartments. The catalyst CA as the bed material circulates between the compartments.

[0220] A raw material A including coal, biomass, municipal wastes, industrial wastes, RDF, waste plastics, etc. is gasified by a gasification apparatus 51, and a generated gas GA is delivered to a dust collector 52. The dust collector 52 removes char CX and ash J contained in the generated gas GA, and delivers the generated gas GA to the reaction chamber 56-1 of the fluidized-bed catalytic reaction apparatus 56. In the reaction chamber 56-1 which is in the reducing atmosphere, the generated gas GA is reformed (tar decomposition) while fluidizing the catalyst CA by the generated gas GA, thus producing a product gas GB.

[0221] A mixture of incombustibles I, the char CX, and the ash J from the gasification apparatus 51 is delivered to a sorting apparatus 53, and the incombustibles I are selectively removed by the sorting apparatus 53 and a remaining mixture of the char. CX and the ash J is supplied from the sorting apparatus 53 to a char combustion apparatus 54. In the char combustion apparatus 54, the char CX is combusted. A combustion exhaust gas GC including the ash J from the char combustion apparatus 54 is delivered to a dust collector 55, which removes the ash J. The combustion exhaust gas GC is then delivered to the regeneration chamber 56-2 of the fluidized-bed catalytic reaction apparatus 56.

[0222] The catalyst CA′ which has contributed to the tar decomposition and whose catalytic function has been lowered is delivered from the reaction chamber 56-1 to the regeneration chamber 56-2. In the regeneration chamber 56-2 which is in an oxidizing atmosphere, the degraded catalyst CA′ is regenerated by the heat of the combustion exhaust gas GC. If the catalyst CA′ delivered from the reaction chamber 56-1 contains a large amount of char CX, then the regeneration chamber 56-2 is charged with an oxygen-containing gas for combustion (such as air) to combust the char CX. The catalyst CA which has been regenerated by the sensible heat of the combustion exhaust gas GC and the heat of combustion of the remaining char CX is supplied again to the reaction chamber 56-1.

[0223] In the reaction chamber 56-1, the tar is decomposed (pyrolysis reaction) in the presence of the catalyst CA, thus lowering the temperature in the furnace. The reaction chamber 56-1 is supplied with the quantity of heat required for pyrolysis from the heat carried in by the catalyst CA serving as the bed material supplied from the regeneration chamber 56-2 and the sensible heat of the generated gas GA. The reaction chamber 56-1 of the fluidized-bed catalytic reaction apparatus 56 can be replenished with the catalyst CA.

[0224]
FIG. 26 is a view showing an example of system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention. As with the apparatus shown in FIG. 25, the apparatus shown in FIG. 26 employs the fluidized-bed catalytic reaction apparatus 56 as a catalytic reaction and catalyst regenerating apparatus. However, the apparatus shown in FIG. 26 differs from the apparatus shown in FIG. 25 in that the gasification apparatus 51 comprises a fluidized-bed furnace which is divided into a gasification chamber 51-1 in a reducing atmosphere for gasifying a raw material A and a combustion chamber 51-2 in an oxidizing atmosphere. The gasification chamber 51-1 and the combustion chamber 51-2 are divided by a partition plate (not shown) to allow gases to pass independently through the gasification chamber 51-1 and the combustion chamber 51-2, respectively. A bed material circulates between the compartments.

[0225] A mixture of incombustibles I, char CX, and ash J removed from the gasification chamber 51-1 is delivered to the sorting apparatus 53, and the incombustibles I are selectively removed by the sorting apparatus 53 and the remaining char CX and ash J are supplied from the sorting apparatus 53 to the combustion chamber 51-2. The bed material MX and the char CX from the gasification chamber 51-1 are delivered to the combustion chamber 51-2, and the char CX is combusted in the combustion chamber 51-2. The bed material MX that is heated in the combustion chamber 51-2 is returned again to the gasification chamber 51-1. The dust collecting of the generated gas GA from the gasification chamber 51-1 and the combustion exhaust gas GCfrom the combustion chamber 51-2 is performed respectively by the dust collector 52 and the dust collector 55, and then delivered respectively to the reaction chamber 56-1 and the regeneration chamber 56-2 of the fluidized-bed catalytic reaction apparatus 56, as with the apparatus shown in FIG. 25. The char CX and the ash J which have been removed from the generated gas GA by the dust collector 52 are returned to the combustion chamber 51-2 and the gasification chamber 51-1 for combustion and gasification, if necessary (if the amount of char CX is large). The reaction chamber of the fluidized-bed catalytic reaction apparatus 56 can be replenished with the catalyst CA.

[0226] In the apparatuses shown in FIGS. 25 and 26, the fluidized-bed catalytic reaction apparatus 56 having the reaction chamber 56-1 with the fluidized bed and the regeneration chamber 56-2 with the fluidized bed is used as the catalytic reaction and catalyst regenerating apparatus. However, the catalyst reacting and reproducing apparatus is not limited to the fluidized-bed catalytic reaction apparatus 56, but may comprise an integral combination of a reaction chamber for reforming a generated gas with a catalyst and a regeneration chamber for heating and regenerating the catalyst that has been degraded by gas reforming.

[0227] With the apparatus shown in FIG. 25, the dust collecting of the generated gas GA and the combustion exhaust gas GC that are to be supplied to the fluidized-bed catalytic reaction apparatus 56 is performed respectively in a pre-treatment process by the dust collectors 52 and 55. The fluidized-bed catalytic reaction apparatus 56 which comprises a catalyst fluidized-bed furnace may also be used as a particulate filter and thus as a fluidized-bed catalyst dedusting apparatus 56′ having a dust collecting function, as shown in FIG. 27. In FIG. 27, the degraded catalyst CA′, the ash J, and the char CX from a reaction chamber 56′-1 are delivered to a regeneration chamber 56′-2, and the char CX is combusted to regenerate the degraded catalyst CA′ with the heat of combustion of the char CX in the regeneration chamber 56′-2. The regenerated catalyst CA is returned to the reaction chamber 56′-1, and the ash J is discharged out of the fluidized-bed catalytic reaction apparatus 56.

[0228] Further, with the apparatus shown in FIG. 26, the dust collecting of the generated gas GA and the combustion exhaust gas. GC that are to be supplied to the fluidized-bed catalytic reaction apparatus 56 is performed, respectively, in a pre-treatment process by the dust collectors 52 and 55. The fluidized-bed catalytic reaction apparatus 56 which comprises a catalyst fluidized-bed furnace may also be used as a fluidized-bed catalyst dedusting apparatus 56′ having a dust collecting function, as shown in FIG. 28. In FIG. 28, the degraded catalyst CA′, the ash J, and the char CX from the reaction chamber 56′-1 are delivered to the regeneration chamber 56′-2, and the char CX is combusted to regenerate the degraded catalyst CA′ with the heat of combustion of the char CX in the regeneration chamber 56′-2. The regenerated catalyst CA is returned to the reaction chamber 56′-1, and the ash J is discharged out of the fluidized-bed catalyst dedusting apparatus 56′. The char CX and the ash J from the reaction chamber 56′-1 are delivered to the combustion chamber 51-2 of the gasification apparatus 51.

[0229]
FIG. 29 is a view showing a construction of the furnace portion of the apparatus shown in FIG. 28. As shown in FIG. 29, the gasification apparatus 51 is divided into the gasification chamber 51-1 and the combustion chamber 51-2 by a partition wall 51a. A fluidized bed 51-1a in the gasification chamber 51-1 and a fluidized bed 51-2a in the combustion chamber 51-2 communicate with each other below the lower end of the partition wall 51a. The bed material MX and the char CX move from the fluidized bed 51-1a in the gasification chamber 51-1 into the fluidized bed 51-2a in the combustion chamber 51-2 through a communication passage 51b. The bed material MX which has been heated with the heat of combustion of the char CX in the combustion chamber 51-2 moves from the fluidized bed 51-2a into the fluidized bed 51-1a in the gasification chamber 51-1.

[0230] The fluidized-bed catalyst dedusting apparatus 56′ is divided into the reaction chamber 56′-1 and the regeneration chamber 56′-2 by a partition wall 56′a. A fluidized bed 56′-1a in the reaction chamber 56′-1 and a fluidized bed 56′-2a in the regeneration chamber 56′-2 communicate with each other below the lower end of the partition wall 56′a. The degraded catalyst CA′, the ash J, and the char CX move from the fluidized bed 56′-1a in the reaction chamber 56′-1 into the fluidized bed 56′-2a in the regeneration chamber 56′-2 through a communication passage 56′b. The catalyst CA which has been heated with the heat of combustion of the char CX in the regeneration chamber 56′-2 is supplied to the fluidized bed 56′-1a in the reaction chamber 56′-1.

[0231] The raw material A is gasified in the gasification chamber 51-1 in the gasification apparatus 51, and the mixture of the generated gas GA, the ash J, and the char CX is supplied to the reaction chamber 56′-1 in the fluidized-bed catalyst dedusting apparatus 56′. The generated gas GA is reformed (tar decomposition) by the catalyst CA into the product gas GB, which is discharged. The combustion exhaust gas GC from the combustion chamber 51-2 in the gasification apparatus 51 is supplied to the regeneration chamber 56′-2 in the fluidized-bed catalyst dedusting apparatus 56. The combustion exhaust gas GC contributes to the heating and regeneration of the degraded catalyst CA′ in the regeneration chamber 56′-2, and is then discharged.

[0232]
FIG. 30 is a view showing an example of a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention. The apparatus shown in FIG. 30 comprises a single integrated apparatus which integrates the gasification apparatus 51 and the fluidized-bed catalyst dedusting apparatus 56′ shown in FIG. 28. As shown in FIG. 30, the gasification apparatus 51 and the fluidized-bed catalyst dedusting apparatus 56′ are integrated into a single fluidized-bed furnace 60. Operation of the gasification apparatus 51 and the fluidized-bed catalyst dedusting apparatus 56′ is substantially the same as the apparatus shown in FIG. 28, and will not be described in detail below.

[0233]
FIG. 31 is a view showing a construction of the furnace portion of the apparatus shown in FIG. 31. As shown in FIG. 31, the gasification apparatus 51 and the fluidized-bed catalyst dedusting apparatus 56′ are integrated into the single fluidized-bed furnace 60, which includes the fluidized-bed catalyst dedusting apparatus 56′ in its upper portion and the gasification apparatus 51 in its lower portion. The gasification chamber 51-1 and the combustion chamber 51-2 in the gasification apparatus 51, and the reaction chamber 56′-1 and the regeneration chamber 56′-2 in the fluidized-bed catalyst dedusting apparatus 56′ are divided by a partition wall 61. The generated gas GA which is produced in the gasification chamber 51-1 in the gasification apparatus 51 is supplied through a distributor plate 62 at the bottom of the reaction chamber 56′-1 in the fluidized-bed catalyst dedusting apparatus 56′ to the fluidized bed 56′-1a in the reaction chamber 56′-1. The combustion gas GC produced in the combustion chamber 51-2 is supplied through the distributor plate 62 at the bottom of the regeneration chamber 56′-2 to the fluidized bed 56′-2a in the regeneration chamber 56′-2.

[0234] When a raw material A is gasified in the gasification chamber 51-1 in the gasification apparatus 51, the generated gas GA is simultaneously reformed (tar decomposition) by the catalyst CA. The generated gas GA is also injected through the distributor plate 62 at the bottom of the reaction chamber 56′-1 in the fluidized-bed catalyst dedusting apparatus 56′ into the fluidized bed 56′-1a in the reaction chamber 56′-1. In the fluidized bed 56′-1a, the generated gas GA is brought into contact with the catalyst CA, and further reformed into a completely reformed product gas GB, which is then discharged. The combustion exhaust gas GC from the combustion chamber 51-2 in the gasification apparatus 51 is injected through the distributor plate 62 at the bottom of the regeneration chamber 56′-2 in the fluidized-bed catalyst dedusting apparatus 56′ into the fluidized bed 56′-2a in the regeneration chamber 56′-2. The combustion exhaust gas GC is then turned into a clean combustion exhaust gas GC, which is discharged.

[0235]
FIG. 33 is a view showing a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention. For decomposing tar by allowing the reactions of steam reforming and carbon dioxide reforming to progress, it is necessary to use a catalyst suitable for those reactions and also to provide a sufficient amount of reforming gas GR required for the reforming reactions at the inlet of a gas reforming apparatus 12. A generated gas GA from a gasification apparatus 11 usually contains H2O and CO2, and H2O and CO2 need to be contained at a stoichiometric ratio ranging from 1 to 3 (the stoichiometric ratio required to decompose tar is taken as 1), and hence, if necessary, as shown in FIG. 33, steam (H2O) or carbon dioxide (CO2) are charged as the reforming gas GR into the inlet of the gas reforming apparatus 12. The temperature in the gas reforming apparatus 12 is in the range from 700 to 1000° C., or preferably from 800 to 950° C.

[0236] In the above example, a catalyst regenerating apparatus 13 has a function to heat impurities on the catalyst CA to regenerate the catalyst CA. While the function of the catalyst regenerating apparatus 13 is to heat the catalyst CA, the heating of the catalyst CA is not equivalent to the regeneration of the catalyst CA. The catalyst CA may need not only heating, but also some other reactions, in order to be regenerated. However, this does not necessarily mean that the catalyst CA does not need to be heated in order to be regenerated. Since certain temperatures need to be kept in the catalyst regenerating apparatus 13 and the gas reforming apparatus 12, the catalyst CA is required to receive heat in the catalyst regenerating apparatus 13. In summary, the catalyst CA which has been inactivated and degraded by depositing and adsorbing impurities in the gas reforming apparatus 12 is regenerated, and heat (maintenance of reaction temperature) required for the gas reforming apparatus 12 and the catalyst regenerating apparatus 13 is supplied.

[0237] By supplying heat to the catalyst CA, the degraded catalyst CA′ is regenerated. In addition, since the supplied heat is also used to keep temperatures required in the gas reforming apparatus 12 and the catalyst regenerating apparatus 13, such heat acts to heat the catalyst CA. Because the reaction in the gas reforming apparatus 12 is an endothermic reaction, the heating of the catalyst CA in the catalyst regenerating apparatus 13 is important in maintaining the temperature in the gas reforming apparatus 12.

[0238] Specific regenerative reactions for regenerating the catalyst include the following reactions {circumflex over (1)} through {circumflex over (4)}:

[0239] {circumflex over (1)} Combustion (oxidizing) regeneration (regenerative gas=oxygen):

[0240] Carbon C, sulfur S, and the like deposited on the surface of the catalyst are removed by combustion. This reaction is an exothermic reaction as indicated below.

C+O2→CO2

S+O2→SO2

[0241] This reaction is a reaction to remove, by way of combustion, carbon that is generated by a side reaction of the above cracking reaction. The same regenerative process may be considered for sulfur S. Although this reaction is certainly required, oxygen (O2) is also required as a regenerative gas. Oxygen may be pure oxygen, air, an exhaust gas containing residual oxygen, or the like. Since the reaction is an exothermic reaction, the generated heat may be used as a heat source.

[0242] {circumflex over (2)} Hydrogenation regeneration (regenerative gas=hydrogen):

[0243] A catalyst which has been oxidized, chlorinated, or sulfurated is regenerated by way of reduction (CA represents the catalyst, typically a transition metal such as Pt or the like). This reaction is an endothermic reaction as indicated below.

CACl+0.5H2→CA+HCl

CAS+H2→CA+SO2

CAO+H2→CA+H2O

[0244] This reaction serves to regenerate the catalyst by way of hydrogenation. The catalyst (transition metal such as Pt or the like in the catalyst) which has been oxidized, chlorinated or sulfurated is converted into a metal in a reduced state by reduction in a hydrogen-containing gas, thereby regenerating the catalyst.

[0245] {circumflex over (3)} Steam regeneration (regenerative gas=steam):

[0246] A catalyst which has chlorinated or sulfurated is regenerated by way of reduction (CA represents the catalyst, typically Ca, Al, Si, or Mg). This reaction is an endothermic reaction as indicated below.

CACl2+H2O→CAO+2HCl

CAS+H2O→CAO+H2S

[0247] This reaction serves to regenerate the catalyst by way of hydrogenation. The catalyst which has chlorinated or sulfurated is regenerated by way of reduction in the same manner as the above process {circumflex over (2)}.

[0248] {circumflex over (4)} Heating regeneration (regenerative gas=high-temperature exhaust gas or the like):

[0249] Low-melting-point metals (Na, K, Pb, Hg, etc.) melted on the surface of the catalyst are removed by heating evaporation. This reaction is an endothermic reaction.

[0250] In the above embodiment, the heat source of the gas reforming apparatus 12 is process waste heat TP, specifically, the sensible heat of the combustion exhaust gas GC that is produced by combusting the char CX. However, the heat source of the gas reforming apparatus 12 is not limited to the above heat, but may be the heat generated upon the combustion (oxidizing) regeneration {circumflex over (1)} (heat generated when carbon C, sulfur S, etc. are combusted), the heat generated when part of the generated gas is combusted, or a combination of these heats. Alternatively, the quantity of heat held by the raw material itself may be used so as not to use any auxiliary fuels.

[0251]
FIG. 34 is a view showing a system construction of an apparatus for carrying out a combustible gas reforming method according to the present invention. As shown in FIG. 34, the catalyst regenerating apparatus 13 is supplied with process waste heat TP and a regenerative gas GT, and emits a combustion exhaust gas GC. The regenerative gas GT comprises oxygen (O2) (pure oxygen, air, or exhaust gas), hydrogen (H2) (pure hydrogen, hydrogen-containing off-gas, or the like), or steam (H2O). The catalyst CA is regenerated by any of the regenerating processes {circumflex over (1)} through {circumflex over (4)}. The temperature in the catalyst regenerating apparatus 13 is in the range from 800 to 1000° C., or preferably from 900 to 1000° C.

[0252]
FIG. 35 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus in which the sensible heat of the combustion exhaust gas GC is employed. A gasification apparatus 11 comprises a gasification chamber 11-1 and a char combustion chamber 11-2. A bed material MX and char CX are supplied from the gasification chamber 11-1 to the char combustion chamber 11-2. The bed material MX is supplied from the char combustion chamber 11-2 to the gasification chamber 11-1. A gas reforming apparatus 12 is supplied with a reforming gas GR and also with a generated gas GA from the gasification chamber 11-1. A catalyst regenerating apparatus 13 is supplied with a combustion exhaust gas GC from the char combustion chamber 11-2. A degraded catalyst CA′ is supplied from the gas reforming apparatus 12 to the catalyst regenerating apparatus 13, and a regenerated catalyst CA is supplied from the catalyst regenerating apparatus 13 to the gas reforming apparatus 12. The catalyst regenerating process may be used for the combustion (oxidizing) regeneration or the heating regeneration.

[0253]
FIG. 36 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus in which the heat of the regenerative reaction is employed. The catalyst regenerating apparatus 13 is supplied with the regenerative gas GT, which regenerates the catalyst (combustion regeneration by oxygen-containing gas). The catalyst regenerating apparatus 13 thus regenerates the catalyst and serves as a heat source. In this case, since it is not necessary to use the combustion exhaust gas GC that is generated by combusting the char CX, the gasification apparatus 11 may comprise a partial combustion gasification furnace. The catalyst regenerating process may be used for the combustion (oxidizing) regeneration only.

[0254]
FIG. 37 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus in which both the sensible heat of the combustion exhaust gas GC and the heat of the regenerative reaction are employed. The gas reforming apparatus 12 is supplied with the reforming gas GR and also with the generated gas GA from the gasification chamber 11-1. The regenerative gas GT to be supplied to the catalyst regenerating apparatus 13 exchanges heat with the combustion exhaust gas GC from the char combustion chamber 11-2 in a heat exchanger 70, and hence is heated and supplied to the catalyst regenerating apparatus 13. The heat exchanger 70 for heating the regenerative gas GT comprises a high-temperature heat exchanger made of special cast steel or ceramics that can be used in a temperature range of 700 to 1000° C. The catalyst regenerating process may be used for the combustion (oxidizing) regeneration, the hydrogenation regeneration, or the steam regeneration.

[0255]
FIG. 38 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus in which the sensible heat of the combustion exhaust gas GC and the heat of the regenerative reaction are employed. The gas reforming apparatus 12 is supplied with the reforming gas GR and also with the generated gas GA from the gasification chamber 11-1. The generated gas GA exchanges heat with the combustion exhaust gas GC from the char combustion chamber 11-2 in a heat exchanger 71, and hence is heated and supplied to the gas reforming apparatus 12. The catalyst regenerating apparatus 13 is supplied with the regenerative gas GT. The heat exchanger 71 for heating the generated gas GA comprises a high-temperature heat exchanger made of special cast steel or ceramics that can be used in a reducing atmosphere in a temperature range of 700 to 1000° C. The catalyst regenerating process may be used for the combustion (oxidizing) regeneration, the hydrogenation regeneration, or the steam regeneration.

[0256]
FIG. 39 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus in which the sensible heat of the combustion exhaust gas GC and the heat of the regenerative reaction are employed. The reforming gas GR that is supplied to the gas reforming apparatus 12 exchanges heat with the combustion exhaust gas GC from the char combustion chamber 11-2 in a heat exchanger 72, and hence is heated and supplied to the gas reforming apparatus 12. The gas reforming apparatus 12 is supplied with the generated gas GA from the gasification chamber 11-1. The catalyst regenerating apparatus 13 is supplied with the regenerative gas GT. The heat exchanger 72 for heating the reforming gas GR comprises a high-temperature heat exchanger made of special cast steel or ceramics that can be used in a temperature range of 700 to 1000° C. The catalyst regenerating process may be used for the combustion (oxidizing) regeneration, the hydrogenation regeneration, or the steam regeneration.

[0257]
FIG. 40 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus in which the sensible heat of the combustion exhaust gas GC and the heat of the regenerative reaction are employed. The gas reforming apparatus 12 is supplied with the reforming gas GR and also with the generated gas GA from the gasification chamber 11-1. The catalyst regenerating apparatus 13 is supplied with the regenerative gas GT and also with the combustion exhaust gas GC from the char combustion chamber 11-2. The catalyst regenerating process may be used for the combustion (oxidizing) regeneration, the hydrogenation regeneration, or the steam regeneration.

[0258] Any apparatus shown in FIGS. 37, 38, 39, and 40 may be used in the combustion (oxidizing) regeneration process, the hydrogenation regeneration process, and the steam regeneration process. However, since the hydrogenation regeneration process and the steam regeneration process are based on an endothermic reaction and do not serve as a heat source, they are effective only when the sensible heat of the combustion exhaust gas GC is sufficient in quality. In the combination of the heat of the regenerating reaction and another heat source, even an endothermic reaction such as the hydrogenation regeneration is effective as a process if heat is supplemented with another heat source, and hence the process is practical even when the heat of the regenerative reaction acts negatively.

[0259]
FIG. 41 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus in which the heat of combustion of the generated gas is employed. The catalyst regenerating apparatus 13 is supplied with part of the generated gas GA from the gasification apparatus 11 and also with air L (O2). In the catalyst regenerating apparatus 13, the degraded catalyst CA′ is regenerated with heat by removing metals (Na, K, Pb, Hg, etc.) having low melting point melted on the surface of the catalyst by way of heating evaporation.

[0260]
FIG. 42 is a view showing an example a construction of a catalyst regenerating and gas reforming apparatus in which the heat of the regenerative reaction and the heat of combustion of the generated gas are employed. The gas reforming apparatus 12 is supplied with the reforming gas GR and also with part of the generated gas GA from the gasification apparatus 11. The catalyst regenerating apparatus 13 is supplied with part of the generated gas GA from the gasification apparatus 11 and also with the regenerative gas GT and air L (O2). The catalyst regenerating process may be used for the combustion (oxidizing) regeneration, the hydrogenation regeneration, or the steam regeneration.

[0261]
FIG. 43 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus in which the sensible heat of the combustion exhaust gas GC and the heat of combustion of the generated gas are employed. The gas reforming apparatus 12 is supplied with the reforming gas GR and also with the generated gas GA from the gasification chamber 11-1. The generated gas GA exchanges heat with the combustion exhaust gas GC from the char combustion chamber 11-2 in the heat exchanger 71, and hence is heated and supplied. The catalyst regenerating apparatus 13 is supplied with part of the generated gas GA which has been heated by the heat exchanger 71 and also with air L (O2). The catalyst regenerating process may be used for the heating regeneration.

[0262]
FIG. 44 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus in which both the sensible heat of the combustion exhaust gas GC and the heat of combustion of the generated gas are employed. The gas reforming apparatus 12 is supplied with the reforming gas GR and also with part of the generated gas GA from the gasification chamber 11-1. The catalyst regenerating apparatus 13 is supplied with part of the generated gas GA from the gasification apparatus 11 and also with air L (O2). The air L (O2) is heated by the combustion exhaust gas GC from the char combustion chamber 11-2 in the heat exchanger 70. The catalyst regenerating process may be used for the heating regeneration.

[0263]
FIG. 45 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus in which the sensible heat of the combustion exhaust gas GC and the heat of combustion of the generated gas are employed. The gas reforming apparatus 12 is supplied with the reforming gas GR that has been heated by the combustion exhaust gas GC from the char combustion chamber 11-2 in the heat exchanger 72, and also with part of the generated gas GA from the gasification chamber 11-1. The catalyst regenerating apparatus 13 is supplied with part of the generated gas GA from the gasification chamber 11-1 and also with air L (O2). The catalyst regenerating process may be used for the heating regeneration.

[0264]
FIG. 46 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus in which the sensible heat of the combustion exhaust gas and the heat of combustion of the generated gas are employed. The gas reforming apparatus 12 is supplied with the reforming gas GR and also with part of the generated gas GA from the gasification chamber 11-1. The catalyst regenerating apparatus 13 is supplied with part of the generated gas GA from the gasification chamber 11-1 and also with the combustion exhaust gas GC from the char combustion chamber 11-2 and air L (O2). The catalyst regenerating process may be used for the heating regeneration.

[0265]
FIG. 47 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus in which the heat of combustion of the generated gas, the sensible heat of the combustion exhaust gas GC, and the heat of the regenerative reaction are employed. The gas reforming apparatus 12 is supplied with the reforming gas GR and also with part of the generated gas GA from the gasification chamber 11-1. The generated gas GA exchanges heat with the combustion exhaust gas GC from the char combustion chamber 11-2 in the heat exchanger 71, and hence is heated and supplied. The catalyst regenerating apparatus 13 is supplied with part of the generated gas GA which has been heated and also with the regenerative gas GT and air L (O2). The catalyst regenerating process may be used for the combustion (oxidizing) regeneration, the hydrogenation regeneration, or the steam regeneration.

[0266]
FIG. 48 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus in which the heat of combustion of the generated gas, the sensible heat of the combustion exhaust gas GC, and the heat of the regenerative reaction are employed. The gas reforming apparatus 12 is supplied with the reforming gas GR and also with part of the generated gas GA from the gasification chamber 11-1. The catalyst regenerating apparatus 13 is supplied with the regenerative gas GT and air L (O2) that has been heated by a heat exchange with the combustion exhaust gas GC from the char combustion chamber 11-2 in the heat exchanger 70. The catalyst regenerating process may be used for the combustion (oxidizing) regeneration, the hydrogenation regeneration, or the steam regeneration.

[0267]
FIG. 49 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus in which the heat of combustion of the generated gas, the sensible heat of the combustion exhaust gas GC, and the heat of the regenerative reaction are employed. The gas reforming apparatus 12 is supplied with the reforming gas GR and also with part of the generated gas GA from the gasification chamber 11-1. The catalyst regenerating apparatus 13 is supplied with air L (O2) and the regenerative gas GT that has been heated by a heat exchange with the combustion exhaust gas GC from the char combustion chamber 11-2 in the heat exchanger 70. The catalyst regenerating process may be used for the heating regeneration.

[0268]
FIG. 50 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus in which the heat of combustion of the generated gas, the sensible heat of the combustion exhaust gas GC, and the heat of the regenerative reaction are employed. The gas reforming apparatus 12 is supplied with the reforming gas GR that has been heated by a heat exchange with the combustion exhaust gas GC from the char combustion chamber 11-2 in the heat exchanger 72 and also with part of the generated gas GA from the gasification chamber 11-1. The catalyst regenerating apparatus 13 is supplied with part of the generated gas GA, air L (O2), and the regenerative gas GT. The catalyst regenerating process may be used for the heating regeneration.

[0269]
FIG. 51 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus in which the heat of combustion of the generated gas, the sensible heat of the combustion exhaust gas GC, and the heat of the regenerative reaction are employed. The gas reforming apparatus 12 is supplied with the reforming gas GR and also with part of the generated gas GA from the gasification chamber 11-1. The catalyst regenerating apparatus 13 is supplied with part of the generated gas GA, air L (O2), the regenerative gas GT, and the combustion exhaust gas GC from the char combustion chamber 11-2. The catalyst regenerating process may be used for the heating regeneration.

[0270] The catalyst that is degraded in the gas reforming apparatus needs to be regenerated by the catalyst regenerating apparatus. Therefore, it is necessary for the catalyst particles to circulate continuously or intermittently. In the above embodiments, as shown in FIG. 52, a gas reforming chamber 201 and a catalyst regeneration chamber 202 are integrated into a fluidized bed 200. However, the catalyst regenerating and gas reforming apparatus is also available in configurations described below. In FIG. 52, reference numerals 203, 204 represent cyclone-type dust collectors, and the gas reforming chamber 201 is supplied with the generated gas GA from its bottom and the catalyst regeneration chamber 202 is supplied with the combustion exhaust gas GC from its bottom.

[0271]
FIG. 53 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus. The catalyst regenerating and gas reforming apparatus shown in FIG. 53 comprises a bed material circulation dual fluidized bed system having a gas reforming apparatus 210 and a catalyst regenerating apparatus 211 each comprising an entrained bed. In the respective layers of the gas reforming apparatus 210 and the catalyst regenerating apparatus 211, a gas is supplied to each column at a superficial velocity that is required for the catalyst particles to move at a terminal velocity. The degraded catalyst (particles) CA′ which flies out from the gas reforming apparatus 210 is separated from the product gas GB in a cyclone-type dust collector 212, and is then supplied to the catalyst regenerating apparatus 211. The regenerated catalyst (particles) CA which flies out from the catalyst regenerating apparatus 211 is separated from the combustion exhaust gas GC in a cyclone-type dust collector 213, and is then supplied to the gas reforming apparatus 210. In this manner, the catalyst particles are continuously circulated between the two columns.

[0272]
FIG. 54 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus. The catalyst regenerating and gas reforming apparatus shown in FIG. 54 comprises a bed material circulation dual fluidized bed system having a gas reforming apparatus 220 and a catalyst regenerating apparatus 221 each comprising a dense fluidized bed. The catalyst CA heated and regenerated by the catalyst regenerating apparatus 221 overflows the catalyst regenerating apparatus 221 into the gas reforming apparatus 220. The degraded catalyst CA′ is removed from the bottom of the gas reforming apparatus 220 and delivered by pneumatic transportation 224 to the catalyst regenerating apparatus 221. The pneumatic transportation 224 comprises air L or the like having a pressure suitable for delivering the degraded catalyst CA′. The catalyst (particles) CA′ which flies out from the gas reforming apparatus 220 is separated from the product gas GB in a cyclone-type dust collector 222, and returned to the gas reforming apparatus 220. The regenerated catalyst (particles) CA which flies out from the catalyst regenerating apparatus 221 is separated from combustion exhaust gas GC in a cyclone-type dust collector 223, and returned to the catalyst regenerating apparatus 221. In this manner, the catalyst particles are continuously circulated between the two columns.

[0273]
FIG. 55 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus. The catalyst regenerating and gas reforming apparatus shown in FIG. 55 is of a design similar to the catalyst regenerating and gas reforming apparatus shown in FIG. 54, but differs therefrom in that the degraded catalyst (particles) CA′ from the gas reforming apparatus 220 overflows into the catalyst regenerating apparatus 221, and the catalyst CA which is heated and regenerated by the catalyst regenerating apparatus 221 is delivered by the pneumatic transportation 224 to the gas reforming apparatus 220. The pneumatic transportation 224 comprises the generated gas GA, a nitrogen gas (N2), steam (H2O), carbon dioxide (CO2), or a combustible gas such as propane gas or the like having a pressure suitable for delivering the catalyst CA.

[0274]
FIG. 56 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus. The catalyst regenerating and gas reforming apparatus shown in FIG. 56 comprises a bed material circulation dual fluidized bed system having a gas reforming apparatus 220 and a catalyst regenerating apparatus 221 each comprising a dense fluidized bed. The catalyst CA heated and regenerated by the catalyst regenerating apparatus 221 overflows into the gas reforming apparatus 220, as with the catalyst regenerating and gas reforming apparatus shown in FIG. 54. The catalyst CA′ degraded in the gas reforming apparatus 220 is removed from the bottom of the gas reforming apparatus 220 and delivered to the catalyst regenerating apparatus 221 by a mechanical feeding means such as a screw conveyor 225 and an elevator 226.

[0275]
FIG. 57 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus. The catalyst regenerating and gas reforming apparatus shown in FIG. 57 is similar to the catalyst regenerating and gas reforming apparatus shown in FIG. 56, but differs therefrom in that the degraded catalyst CA′ from the gas reforming apparatus 220 overflows into the catalyst regenerating apparatus 221, and the catalyst CA heated and regenerated by the catalyst regenerating apparatus 221 is removed from the bottom of the catalyst regenerating apparatus 221 and delivered to the gas reforming apparatus 220 by a mechanical feeding means such as a screw conveyor 225 and an elevator 226.

[0276]
FIG. 58 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus. The catalyst regenerating and gas reforming apparatus shown in FIG. 58 comprises a bed material circulation dual fluidized bed system having a gas reforming apparatus 220 and a catalyst regenerating apparatus 221 each comprising a dense fluidized bed. The degraded catalyst CA′ from the gas reforming apparatus 220 overflows into the catalyst regenerating apparatus 221, and the catalyst CA heated and regenerated by the catalyst regenerating apparatus 221 also overflows into the gas reforming apparatus 220.

[0277]
FIG. 59 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus. The catalyst regenerating and gas reforming apparatus shown in FIG. 59 comprises a bed material circulation dual fluidized bed system having a gas reforming apparatus 210 comprising an entrained bed and a catalyst regenerating apparatus 221 comprising a dense fluidized bed. The degraded catalyst (particles) CA′ which flies out from the gas reforming apparatus 210 is separated from the product gas GB in the cyclone-type dust collector 212, and is then supplied to the catalyst regenerating apparatus 221. The catalyst CA heated and regenerated by the catalyst regenerating apparatus 221 overflows into the gas reforming apparatus 210.

[0278]
FIG. 60 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus. The catalyst regenerating and gas reforming apparatus shown in FIG. 60 is similar to the catalyst regenerating and gas reforming apparatus shown in FIG. 59, but differ therefrom in that the gas reforming apparatus 220 comprises a dense fluidized bed and the catalyst regenerating apparatus 211 comprises an entrained bed. The heated and regenerated catalyst CA which flies out from the catalyst regenerating apparatus 211 is separated from the combustion exhaust gas GC in the cyclone-type dust collector 213, and is then delivered to the gas reforming apparatus 220. The degraded catalyst CA′ from the gas reforming apparatus 220 overflows into the catalyst regenerating apparatus 211.

[0279]
FIG. 61 is a view showing an example of a construction of a catalyst regenerating and gas reforming apparatus. The catalyst regenerating and gas reforming apparatus shown in FIG. 61 comprises a fixed bed switching system having catalyst beds 230, 231. Each of the catalyst may be particulate, cylindrical, or honeycomb-shaped. When the catalyst bed 230 is used as a gas reforming apparatus and is supplied with the generated gas GA, the other catalyst bed 231 is used as a catalyst regenerating apparatus and is supplied with the combustion exhaust gas GC. When the catalyst CA of the catalyst bed 230 becomes inactive upon elapse of a certain period of time, the catalyst bed 230 is supplied with the combustion exhaust gas GC to regenerate the degraded catalyst CA′, and the catalyst bed 231 is supplied with the generated gas GA to reform the generated gas GA. Switching between the generated gas GA and the combustion exhaust gas GC is performed by operating valves V1 through V8.

[0280] In the catalyst regenerating and gas reforming apparatus shown in FIG. 61, the catalyst is regenerated intermittently. Though no problem arises by intermittently regenerating the catalyst, since an exchange of heat is required, if the heat capacity of the catalyst is not sufficient, then the catalyst beds 230, 231 should comprise not only a catalyst, but also a heat storage such as ceramic or the like, or should comprise, as shown in FIGS. 62A and 62B, two catalyst beds 232, 233 having wide areas held in contact with each other so as to prevent the generated gas GA and the combustion exhaust gas GC from being mixed with each other, thereby performing heat conduction therebetween. FIG. 62A is a vertical cross-sectional view of the catalyst regenerating and gas reforming apparatus, and FIG. 62B is a cross-sectional view taken along line A-A of FIG. 62A.

[0281]
FIGS. 63A through 63C are views showing an example of a construction of a catalyst regenerating and gas reforming apparatus. The catalyst regenerating and gas reforming apparatus shown in FIGS. 63A through 63C comprises a rotary fixed-bed system. A cylindrical casing 234 houses a honeycomb-shaped packed bed (cylindrical) 236 of catalyst particles which is rotatably supported by a rotational shaft 237. Chambers 234a, 234b are defined respectively in opposite ends of the casing 234. Each of the chambers 234a, 234b is divided into upper and lower compartments by two partition plates 239 that are disposed so as to sandwich the rotational shaft 237. The packed bed 236 of catalyst particles can be rotated by an actuator 235.

[0282] The upper compartment of the chamber 234a is supplied with the generated gas GA, and the lower compartment of the chamber 234a is supplied with the combustion exhaust gas GC. The reformed product gas GB is discharged from the upper compartment of the chamber 234b, and the combustion exhaust gas GC is discharged from the lower compartment of the chamber 234b. A purge gas GPA such as a nitrogen gas (N2) or the like is caused to flow between the partition plates 239 to prevent the generated gas GA and the combustion exhaust gas GC from being mixed with each other. The packed bed 236 of catalyst particles has an upper half that serves as a gas reforming region at all times, and a lower half that serves as a catalyst regenerating region at all times. The catalyst of the packed bed 236 is semicontinuously regenerated. In this case, if the heat capacity of the catalyst is not sufficient, then it is necessary that a heat storage be provided in a portion of the packed bed 236 to perform a heat transfer between the gas reforming region and the catalyst regenerating region. FIG. 63A is a vertical cross-sectional view of the catalyst regenerating and gas reforming apparatus. FIG. 63B is a cross-sectional view taken along line A-A of FIG. 63A. FIG. 63C is a view illustrative of the manner in which the purging gas GPA flows.

[0283]
FIG. 64 is a view showing an example of a system construction of a gasification apparatus. The gasification apparatus shown in FIG. 64 has a pyrolysis kiln furnace 240 and a fluidized-bed char combustion furnace 241. A raw material A is fed by a feeding mechanism 242 into the rotary pyrolysis kiln furnace 240 which is slightly inclined, and pyrolyzed in the rotary pyrolysis kiln furnace 240 to produce a generated gas GA containing tar and also to simultaneously produce incombustibles I and char CX. A steam U is charged into the rotary pyrolysis kiln furnace 240 for supplying heat and also promoting the pyrolysis.

[0284] The incombustibles I and the char CX which are discharged from the rotary pyrolysis kiln furnace 240 are temporarily stored in a hopper 243, and then charged through a double damper 245 and a feeding mechanism 246 into the fluidized-bed char combustion furnace 241. The incombustibles I and the char CX are temporarily stored in the hopper 243 because the incombustibles I and the char CX are intermittently or continuously supplied through the double damper 245 to the fluidized-bed char combustion furnace 241 for thereby preventing a combustion gas from leaking from the fluidized-bed char combustion furnace 241. The fluidized-bed char combustion furnace 241 has a dense fluidized bed comprising sand as a bed material, and air, or oxygen, or a mixture of air or oxygen, and steam is utilized as a fluidizing gas. The air is supplied to the fluidized bed at an air ratio of about 1.2 to 2 of the amount of air that is required to combust the char CX. In the fluidized-bed char combustion furnace 241, the char CX is combusted, and the incombustibles I are simultaneously discharged from the lower portion of the fluidized bed.

[0285] When the char CX is combusted in the fluidized-bed char combustion furnace 241, any remaining unburned char CX and a combustion exhaust gas GC are delivered from the fluidized-bed char combustion furnace 241 to a cyclone-type dust collector 247 where the combustion exhaust gas GC and the char CX are separated from each other. The char CX is returned to the fluidized-bed char combustion furnace 241, and the combustion exhaust gas GC (900 to 1000° C.) is delivered to a heat exchanger 248 in which a heat exchange is performed between the generated gas GA and the combustion exhaust gas GC. The generated gas GA is heated, and delivered to a gas reforming apparatus. The combustion exhaust gas GC from the heat exchanger 248 is supplied to the rotary pyrolysis kiln furnace 240. The rotary pyrolysis kiln furnace 240 is of a double-walled structure having an inner space through which the row material A flows and an outer space through which the combustion exhaust gas GC flows to heat the inner space.

[0286]
FIG. 65 is a view showing an example of a system construction of a gasification apparatus. The gasification apparatus shown in FIG. 65 has a partial combustion gasification furnace 250 which is supplied with a raw material A by a feeding mechanism. The partial combustion gasification furnace 250 is also supplied with a fluidizing gas which comprises air L (or oxygen O2) supplied at an air ratio of about 0.2 to 0.5 of the amount of air that is required to combust the raw material A. A steam U may be added to the air L. By using the steam U, gasification of the raw material A can be promoted. When part of the raw material A is combusted by the charged air (or oxygen O2), the temperature of the fluidized bed is maintained, and the quantity of heat required to pyrolyze and gasify the raw material A is provided. The partial combustion gasification furnace 250 has a dense fluidized bed comprising sand as a bed material. A dust collector (not shown) is provided at the outlet of the partial combustion gasification furnace 250 for trapping char CX in the generated gas GX and returning the trapped char CX to the partial combustion gasification furnace 250.

[0287]
FIG. 66 is a view showing a system construction of a gasification apparatus which comprises a bed material circulation dual fluidized bed system fluidized-bed gasification furnace. The bed material circulation dual fluidized bed system fluidized-bed gasification furnace comprises a fluidized-bed gasification furnace 251 and a fluidized-bed combustion furnace 252 as major equipment. A bed material circulating means is provided for circulating a bed material MX between the fluidized-bed gasification furnace 251 and the fluidized-bed combustion furnace 252. The bed material MX comprises, at least partly, catalyst particles which comprises alumina or a calcium compound.

[0288] The fluidized-bed gasification furnace 251 is supplied with a raw material A (various wastes such as RDF or waste plastics, coal, biomass, etc.), pyrolyzes and gasifies the raw material A with a gasifying gas V such as steam, and decomposes and reforms the pyrolysis gas. Since at least part of the bed material MX comprises catalyst particles, it is possible to decompose high molecular compounds such as tar, which have heretofore posed problems, within the furnace without increasing the temperature in the furnace. When high molecular compounds such as tar are decomposed, carbon may be deposited on the surface of the catalyst particles in the fluidized-bed gasification furnace 251. A part of the bed material MX containing the char CX and the catalyst particles is supplied from the fluidized-bed gasification furnace 251 to the fluidized-bed combustion furnace 252.

[0289] A generated gas (pyrolysis gas) which is produced in the fluidized-bed gasification furnace 251 is decomposed and reformed to reduce the molecular weight of the generated gas GA by the action of the catalyst particles in the bed material MX. The generated gas GA is supplied to gas turbines or gas engines for power recovery or electric power generation, various liquid fuel synthesizing processes for methanol synthesis, DME synthesis, etc., or various chemical material synthesizing processes.

[0290] The fluidized-bed combustion furnace 252 is supplied with an oxidizing agent W such as air or the like to combust the char CX (mainly unburned carbon) that has been carried together with the bed material MX from the fluidized-bed gasification furnace 251. Since carbon deposited on the surface of the catalyst particles in the fluidized-bed gasification furnace 251 is combusted in the fluidized-bed combustion furnace 252, the catalyst particles are regenerated. The bed material MX containing the regenerated catalyst particles is returned to the fluidized-bed gasification furnace 251, the bed material MX and the regenerated catalyst particles having been heated to a high temperature with the heat of combustion of combustibles such as the char CX in the fluidized-bed combustion furnace 252. The sensible heat of the bed material MX heated to the high temperature is supplied as a heat source for pyrolysis and gasification in the fluidized-bed gasification furnace 251. If the heat required in the fluidized-bed gasification furnace 251 is not obtained only by the combustion of combustibles such as the char CX from the fluidized-bed gasification furnace 251, then an auxiliary fuel X is supplied to the fluidized-bed combustion furnace 252 and combusted in the fluidized-bed combustion furnace 252. A combustion exhaust gas GC discharged from the fluidized-bed combustion furnace 252 is emitted into the atmosphere after the sensible heat is recovered therefrom, harmful substances are removed therefrom, and dust is removed therefrom.

[0291] Since the generated gas GA that has flowed out of the fluidized-bed gasification furnace 251 may contain a large amount of high molecular compounds, in some cases, the generated gas GA should preferably be converted into the gas having a low molecular weight such as hydrogen, carbon monoxide or methane, depending on the use of the generated gas GA at a subsequent stage. In such a case, a cracking apparatus 253 is provided at the subsequent stage of the fluidized-bed gasification furnace 251 for converting high molecular compounds into a product gas (reformed gas) GB having a low molecular weight. The cracking apparatus 253 should preferably be a fluidized-bed type cracking apparatus.

[0292] Absorbing catalyst particles such as a calcium compound may be used as at least part of the bed material MX in order to absorb and remove harmful substances such as chlorine compounds, sulfur compounds, and the like contained in the generated gas GA that has flowed from the fluidized-bed gasification furnace 251.

[0293]
FIG. 67 is a view showing an example of a construction of a gasification apparatus system. As shown in FIG. 67, the gasification apparatus comprises a dense fluidized-bed gasification furnace 261 and a dense fluidized-bed combustion furnace 262 that are connected to each other by two bed material delivery pipes 266. A bed material MX in the dense fluidized-bed gasification furnace 261 and the dense fluidized-bed combustion furnace 262 overflows fluidized beds 261a, 262a into the other furnaces through the bed material delivery pipes 266. At least part of the bed material MX comprises catalyst particles of alumina, a calcium compound, or the like.

[0294] The dense fluidized-bed gasification furnace 261 is supplied with a raw material A, pyrolyzes and gasifies the raw material A with a gasifying agent (gasifying gas) V such as steam, and decomposes and reforms the pyrolysis gas with the gasifying agent V. Since at least part of the bed material MX comprises catalyst particles, it is possible to decompose high molecular compounds such as tar, which have heretofore posed problems, within the furnace without increasing the temperature in the furnace. When high molecular compounds such as tar are decomposed, carbon may be deposited on the surface of the catalyst particles in the dense fluidized-bed gasification furnace 261. The catalyst particles may be made of CaO, FeSiO2, MgSiO2, Al2O3, or the like.

[0295] Char CX generated in the dense fluidized-bed gasification furnace 261 overflows, together with the bed material MX, from the fluidized-bed 261a in the dense fluidized-bed gasification furnace 261 into the bed material delivery pipe 266, and then the char CX and the bed material flow into the dense fluidized-bed combustion furnace 262. A generated gas which is produced in the dense fluidized-bed gasification furnace 261 is supplied to a subsequent process through a cyclone-type dust collector 263 which is provided at a furnace outlet 261b for recovering the bed material MX that flies out from an upper portion of the fluidized bed 261a. The bed material MX that is trapped by the cyclone-type dust collector 263 is returned to the dense fluidized-bed gasification furnace 261.

[0296] The dense fluidized-bed combustion furnace 262 is supplied with an oxidizing agent W such as air and combusts combustibles such as the char CX in the bed material MX that are supplied from the dense fluidized-bed gasification furnace 261 through the bed material delivery pipe 266. Further, carbon or the like deposited on the surface of the catalyst particles by the decomposing and reforming reactions in the dense fluidized-bed gasification furnace 261 is combusted by the oxidizing agent W containing oxygen in the dense fluidized-bed combustion furnace 262, with the result that the catalyst particles are regenerated. The bed material MX containing the regenerated catalyst particles overflows the fluidized bed 262a in the dense fluidized-bed combustion furnace 262 into the bed material delivery pipe 266, and is then returned to the dense fluidized-bed gasification furnace 261, the bed material MX and the regenerated catalyst particles having been heated to a high temperature with the heat of combustion of combustibles such as the char CX in the dense fluidized-bed combustion furnace 262. The sensible heat of the bed material MX heated to the high temperature is supplied as a heat source for pyrolysis and gasification in the fluidized-bed gasification furnace 261.

[0297] If the heat required in the dense fluidized-bed gasification furnace 261 is not supplied only by the combustion of combustibles such as the char CX in the dense fluidized-bed combustion furnace 262, then an auxiliary fuel X may be supplied to the dense fluidized-bed combustion furnace 262 and combusted to heat the bed material MX to a high temperature. A combustion exhaust gas GC discharged from the dense fluidized-bed combustion furnace 262 is emitted into the atmosphere after the scattering bed material MX is trapped by a cyclone-type dust collector 264 provided at a furnace outlet 262b of the dense fluidized-bed combustion furnace 262, the sensible heat of the bed material MX is recovered therefrom, harmful substances are removed therefrom, and dust is removed therefrom. The bed material MX trapped by the cyclone-type dust collector 264 is returned to the dense fluidized-bed combustion furnace 262.

[0298] The product gas GB that has flowed out of the cyclone-type dust collector 263 may contain high molecular compounds. When the product gas GB is preferably required to be further converted into the gas having a low molecular weight, depending on the use of the product gas GB at a subsequent stage, then the product gas GB is supplied to a cracking apparatus 265 for decomposing and reforming the high molecular compounds. The cracking apparatus 265 has a catalyst which may comprise a calcium-based catalyst, an alumina catalyst, an iron-based catalyst, a nickel-based catalyst, or the like. The catalyst may be a formed body such as honeycomb or particulate, and the cracking apparatus 265 may comprise a fixed bed, a moving bed, a fluidized bed, or the like.

[0299] In the cracking process, the carbon deposited on the surface of the catalyst needs to be combusted and removed to regenerate the catalyst. If the cracking apparatus 265 comprises a fixed apparatus, then two or more apparatuses are provided parallel to each other, and the line is switched for a reforming reaction and a catalyst regenerating reaction.

[0300] Further, the cracking apparatus 265 preferably comprises a fluidized bed. In this case, the cracking apparatus 265 is arranged to have two fluidized beds and circulate catalyst particles between the two fluidized beds, with one of the two fluidized beds being used for a reforming reaction and the other for a catalyst regenerating reaction. The fluidized bed for a reforming reaction is supplied with the generated gas GA, and the fluidized bed for a catalyst regenerating reaction is supplied with a gas containing oxygen for combustion such as air or the like.

[0301] If the cracking apparatus 265 comprises a fluidized-bed type cracking apparatus, then it may have internally circulating fluidized beds as shown in FIG. 68 for easily circulating catalyst particles between the fluidized bed for a reforming reaction and the fluidized bed for a catalyst regenerating reaction. Specifically, the cracking apparatus 265 with the internally circulating fluidized beds has a reforming reaction chamber 267 and a catalyst regeneration chamber 268, within the apparatus, separated from each other by a partition wall 270 having an opening 270a disposed in the fluidized bed and interconnecting the reforming reaction chamber 267 and the catalyst regeneration chamber 268. Since catalyst particles circulate between the reforming reaction chamber 267 and the catalyst regeneration chamber 268 through the opening 270a, a product gas (reformed gas) GB and a combustion exhaust gas GC that is produced when the catalyst is regenerated can be recovered without being mixed with each other in the cracking apparatus 265.

[0302] The generated gas GA is supplied to the reforming reaction chamber 267 from its bottom. In the reforming reaction chamber 267, catalyst particles are fluidized, and high molecular compounds contained in the generated gas GA are converted into components having a low molecular weight. A reforming agent (reforming gas) such as steam required for the reforming reaction may be supplied together with the generated gas GA to the reforming reaction chamber 267 from its bottom. The product gas GB which has been converted into components having a low molecular weight is supplied to a subsequent process for power recovery, electric power generation, fuel synthesis, or conversion into chemical materials. Since carbon or the like is deposited on the surface of the catalyst particles, tending to make the catalyst particles inactive, the catalyst particles are delivered to the catalyst regeneration chamber 268 for regenerating the catalyst particles.

[0303] The catalyst regeneration chamber 268 is supplied with an oxidizing agent V from its bottom for fluidizing the catalyst particles that have been supplied from the reforming reaction chamber 267 and combusting and removing the carbon or the like that has been deposited on the surface of the catalyst particles. The catalyst particles are heated to a high temperature by combustion of carbon or the like. The regenerated catalyst particles having a high temperature are returned to the reforming reaction chamber 267. By the circulation of the catalyst particles, the heat that is required for the reforming reaction is supplied to the reforming reaction chamber 267. The combustion exhaust gas GC produced in the catalyst regeneration chamber 268 is emitted out of the system without being mixed with the product gas GB after the combustion exhaust gas GC is lowered in its temperature, dust is removed therefrom, and harmful substances are removed therefrom.

[0304] An interlayer heat transfer pipe 271 may be disposed in the catalyst regeneration chamber 268 for recovering heat to control the temperature of the fluidized bed. The temperature control performed by the interlayer heat transfer pipe 271 makes the temperature of the fluidized bed optimum for the reforming reaction. The catalyst regeneration chamber 268 for combusting the carbon or the like deposited on the surface of the catalyst particles and a heat recovery chamber 269 for recovering heat may be divided by a partition wall 272 disposed in the fluidized bed, and the catalyst particles may be circulated between the catalyst regeneration chamber 268 and the heat recovery chamber 269. In this case, a fluidizing gas N is supplied to the heat recovery chamber 269 from its bottom. The quantity of heat that is recovered in the heat recovery chamber 269 can be controlled by the amount of the fluidizing gas N that is supplied to the heat recovery chamber 269. In this manner, the temperature of the fluidized bed in the catalyst regeneration chamber 268 can easily be controlled without changing the supplied amount of the oxidizing agent V and the height of the fluidized bed.

[0305] The product gas GB that has been decomposed and reformed by the cracking apparatus 265 is supplied to gas turbines or gas engines for power recovery or electric power generation, various liquid fuel synthesizing processes for methanol synthesis or DME synthesis, various chemical material synthesizing processes, or the like.

[0306] Absorbing catalyst particles such as a calcium compound may be used as at least part of the bed material MX in order to absorb and remove harmful substances such as chlorine compounds, sulfur compounds, and the like contained in the generated gas GA that has flowed from the gasification furnace.

[0307]
FIG. 69 is a view showing an example of a system construction of a gasification apparatus according to the present invention. As shown in FIG. 69, the gasification apparatus has two fast fluidized-bed furnaces comprising a fast fluidized-bed gasification furnace 281 and a fast fluidized-bed combustion furnace 282. The two fast fluidized-bed furnaces have respective furnace outlets 281b, 282b connected to respective cyclone-type dust collectors 283, 284. A bed material (particles) which flies out from the respective fluidized beds is separated and recovered by the cyclone-type dust collectors 283, 284, and is then supplied to the other fast fluidized-bed furnaces. At least part of the bed material MX comprises catalyst particles of alumina, a calcium compound, or the like.

[0308] The fast fluidized-bed gasification furnace 281 is supplied with a raw material A, pyrolyzes and gasifies the raw material A with a gasifying agent V such as steam or the like, and decomposes and reforms the pyrolysis gas with the gasifying agent V. Since at least part of the bed material MX comprises catalyst particles, it is possible to decompose high molecular compounds such as tar, which have heretofore posed problems, within the furnace without increasing the temperature in the furnace. When high molecular compounds such as tar are decomposed, carbon may be deposited on the surface of the catalyst particles in the fast fluidized-bed gasification furnace 281. The catalyst particles may be made of CaO, FeSiO2, MgSiO2, Al2O3, or the like.

[0309] Char CX (mainly unburned carbon) that has been produced in the fast fluidized-bed gasification furnace 281 and the bed material MX flow together with the generated gas GA out of the fast fluidized-bed gasification furnace 281, and the char CX and the bed material MX are separated and recovered by the cyclone-type dust collector 283 and supplied to the fast fluidized-bed combustion furnace 282. The generated gas GA which has been produced in the fast fluidized-bed gasification furnace 281 and separated from the char CX and the bed material MX by the cyclone-type dust collector 283 is supplied to a subsequent process.

[0310] The fast fluidized-bed combustion furnace 282 is supplied with an oxidizing agent W such as air or the like and combusts combustibles such as the char in the bed material MX that is supplied from the fast fluidized-bed gasification furnace 281. The carbon or the like deposited on the surface of the catalyst particles in the bed material MX by the decomposing and reforming reactions in the fast fluidized-bed gasification furnace 281 is combusted and removed by a gas containing oxygen in the fast fluidized-bed combustion furnace 282, with the result that the catalyst particles are regenerated. The bed material MX containing the regenerated catalyst particles which have been heated to a high temperature by the heat of combustion of carbon or the like in the fast fluidized-bed combustion furnace 282 flows together with the combustion exhaust gas GC from a furnace outlet 282b into the cyclone-type dust collector 284. The bed material MX is separated and recovered by the cyclone-type dust collector 284, and is then returned to the fast fluidized-bed gasification furnace 281.

[0311] The sensible heat of the bed material MX heated to the high temperature is supplied as a heat source for pyrolysis and gasification in the fast fluidized-bed gasification furnace 281. If the heat required in the fast fluidized-bed gasification furnace 281 is not supplied only by the combustion of combustibles such as the char CX from the fast fluidized-bed combustion furnace 282, then an auxiliary fuel X may be supplied to the fast fluidized-bed combustion furnace 282 and combusted to heat the bed material MX to a high temperature. A combustion exhaust gas GC discharged from the fast fluidized-bed combustion furnace 282 is emitted into the atmosphere after it is separated from the char and the bed material MX by the cyclone-type dust collector 284 provided at the furnace outlet 282b, the sensible heat is recovered therefrom, harmful substances are removed therefrom, and dust is removed therefrom.

[0312] The generated gas GA that has flowed out of the cyclone-type dust collector 283 may contain high molecular compounds. When the generated gas GA is preferably required to be further converted into the gas having a low molecular weight depending on the use of the generated gas GA at a subsequent stage, then the generated gas GA is supplied to a cracking apparatus 285 for decomposing and reforming the high molecular compounds. The cracking apparatus 285 has a catalyst which may comprise a calcium-based catalyst, an alumina catalyst, an iron-based catalyst, a nickel-based catalyst, or the like. The catalyst may be a formed body such as honeycomb or particulate, and the cracking apparatus 285 may comprise a fixed bed, a moving bed, a fluidized bed, or the like.

[0313] The carbon deposited on the surface of the catalyst in the cracking process performed by the cracking apparatus 285 needs to be combusted and removed to regenerate the catalyst. If the cracking apparatus 285 comprises a fixed-bed apparatus, then two or more apparatuses are provided parallel to each other, and the line is switched for a reforming reaction and a catalyst regenerating reaction. Further, the cracking apparatus 285 preferably comprises a fluidized bed. In this case, the cracking apparatus 285 is arranged to have two fluidized beds and circulate catalyst particles between the two fluidized beds, with one of the two fluidized beds being used for a reforming reaction and the other for a catalyst regenerating reaction. The fluidized bed for a reforming reaction is supplied with the generated gas GA, and the fluidized bed for a catalyst regenerating reaction is supplied with a gas containing oxygen such as combustion air or the like.

[0314] If the cracking apparatus 285 comprises a fluidized-bed type cracking apparatus, then it may be constructed and operated in the same manner as the cracking apparatus shown in FIG. 68. The product gas (reformed gas) GB that has been decomposed and reformed by the cracking apparatus 285 is supplied to gas turbines or gas engines for power recovery or electric power generation, various liquid fuel synthesizing processes for methanol synthesis or DME synthesis, various chemical material synthesizing processes, or the like.

[0315] Absorbing catalyst particles such as a calcium compound or the like may be used as at least part of the bed material MX in order to absorb and remove harmful substances such as chlorine compounds, sulfur compounds, and the like contained in the generated gas GA that has flowed from the fast fluidized-bed gasification furnace 281 and separated from the bed material MX by the cyclone-type dust collector 283.

[0316]
FIG. 70 is a view showing an example of a system construction of a gasification apparatus. As shown in FIG. 70, the gasification apparatus has two dense fluidized-bed furnaces comprising a dense fluidized-bed gasification furnace 291 and a dense fluidized-bed combustion furnace 292. A bed material MX moves from the dense fluidized-bed gasification furnace 291 into the dense fluidized-bed combustion furnace 292 in an overflow manner through a bed material delivery pipe 293. However, the bed material MX moves from the dense fluidized-bed combustion furnace 292 into the dense fluidized-bed gasification furnace 291 by a pneumatic transportation system comprising a pneumatic transportation pipe 294. At least part of the bed material MX comprises catalyst particles of alumina, a calcium compound, or the like.

[0317] The dense fluidized-bed gasification furnace 291 is supplied with a raw material A, pyrolyzes and gasifies the raw material A with a gasifying agent (gasifying gas) V such as steam, and decomposes and reforms the pyrolysis gas with the gasifying agent V. Since at least part of the bed material MX comprises catalyst particles, it is possible to decompose high molecular compounds such as tar, which have heretofore posed problems, within the furnace without increasing the temperature in the furnace. When high molecular compounds such as tar are decomposed, carbon may be deposited on the surface of the catalyst particles in the dense fluidized-bed gasification furnace 291. The catalyst particles may be made of CaO, FeSiO2, Al2O3, or the like. Char produced in the dense fluidized-bed gasification furnace 291 overflows, together with the bed material MX, the fluidized bed in the dense fluidized-bed gasification furnace 291 into the bed material delivery pipe 293, and then the char and the bed material MX flow into the dense fluidized-bed combustion furnace 292. The generated gas GA produced in the dense fluidized-bed gasification furnace 291 is supplied to a subsequent process.

[0318] The dense fluidized-bed combustion furnace 292 is supplied with an oxidizing agent V such as air and combusts combustibles such as the char in the bed material MX that are supplied from the dense fluidized-bed gasification furnace 291. Further, carbon or the like deposited on the surface of the catalyst particles by the decomposing and reforming reactions in the dense fluidized-bed gasification furnace 291 is combusted and removed by a gas containing oxygen in the dense fluidized-bed combustion furnace 292, with the result that the catalyst particles are regenerated. The bed material MX containing the regenerated catalyst particles which have been heated to a high temperature by the heat of combustion of combustibles such as carbon or the like in the dense fluidized-bed combustion furnace 292 is returned through the pneumatic transportation pipe 294 to the dense fluidized-bed gasification furnace 291.

[0319] The sensible heat of the bed material MX heated to the high temperature is supplied as a heat source for pyrolysis and gasification in the dense fluidized-bed gasification furnace 291. If the heat required in the dense fluidized-bed gasification furnace 291 is not supplied only by the combustion of combustibles such as the char from the dense fluidized-bed combustion furnace 292, then an auxiliary fuel X may be supplied to the dense fluidized-bed combustion furnace 292 and combusted to heat the bed material MX to a high temperature. A combustion exhaust gas GC discharged from the dense fluidized-bed combustion furnace 292 is emitted into the atmosphere after the sensible heat is recovered therefrom, harmful substances are removed therefrom, and dust is removed therefrom.

[0320] The generated gas GA that has flowed out of the dense fluidized-bed gasification furnace 291 may contain high molecular compounds. When the generated gas GA is preferably required to be further converted into the gas having a low molecular weight depending on the use of the generated gas GA at a subsequent stage, then the generated gas GA is supplied to a cracking apparatus 295 for decomposing and reforming the high molecular compounds. The cracking apparatus 295 has a catalyst which may comprise a calcium-based catalyst, an alumina catalyst, an iron-based catalyst, a nickel-based catalyst, or the like. The catalyst may be a formed body such as honeycomb or particulate, and the cracking apparatus 295 may comprise a fixed bed, a moving bed, a fluidized bed, or the like.

[0321] The carbon deposited on the surface of the catalyst in the cracking process needs to be combusted and removed to regenerate the catalyst. If the cracking apparatus 295 comprises a fixed-bed apparatus, then two or more apparatuses are provided parallel to each other, and the line is switched for a reforming reaction and a catalyst regenerating reaction. Further, the cracking apparatus 295 preferably comprises a fluidized bed. In this case, the cracking apparatus 295 is arranged to have two fluidized beds and circulate catalyst particles between the two fluidized beds, with one of the two fluidized beds being used for a reforming reaction and the other for a catalyst regenerating reaction. The fluidized bed for a reforming reaction is supplied with the generated gas GA, and the fluidized bed for a catalyst regenerating reaction is supplied with a gas containing oxygen such as combustion air or the like.

[0322] If the cracking apparatus 295 comprises a fluidized-bed type cracking apparatus, then it may be constructed and operated in the same manner as the cracking apparatus shown in FIG. 68. The product gas (reformed gas) GB that has been decomposed and reformed by the cracking apparatus 295 is supplied to gas turbines or gas engines for power recovery or electric power generation, various liquid fuel synthesizing processes for methanol synthesis, DME synthesis, etc., or various chemical material synthesizing processes, or the like.

[0323] Absorbing catalyst particles such as a calcium compound or the like may be used as at least part of the bed material in order to absorb and remove harmful substances such as chlorine compounds, sulfur compounds, and the like contained in the generated gas GA that has flowed from the dense fluidized-bed gasification furnace 291.

[0324] The terms “dense fluidized bed”, “fast fluidized-bed”, and “entrained bed” used above refer to a process of floating particles with a gas (supplied from the lower portion of the apparatus to float the particles with its force). These three processes differ from each other based on different amounts of the gas supplied. The amounts of the gas supplied are progressively greater in order: the dense fluidized bed (about 2 m/s)<the fast fluidized-bed (about 3 to 16 m/s)<the entrained bed (15 to 20 m/s). The dense fluidized bed, the fast fluidized-bed, and the entrained bed are defined as follows:

[0325] The dense fluidized bed is a fluidized bed in which most of the particles remain within the apparatus (fluidized-bed furnace or the like) without flying out therefrom. The void fraction in the bed is in the range of 0.6 to 0.8 (volume fraction). Air bubbles having definite interfaces are often present in the bed.

[0326] The fast fluidized-bed is a fluidized bed in which particles fly out by allowing more gas to be supplied than the dense fluidized bed. The void fraction in the fast fluidized-bed is in the range of 0.8 to 0.98 (volume fraction). The fast fluidized-bed often has a (recycling) mechanism for trapping the discharged particles above the apparatus and returning the trapped particles into the fast fluidized-bed.

[0327] The entrained bed is a bed in which particles are delivered on a gas stream by allowing more gas to be supplied than the high-speed fluidized bed. The void fraction in the entrained bed is 0.99 or higher (volume fraction).

[0328] As described above, according to the present invention defined in the claims, the following excellent advantages can be obtained:

[0329] According to the inventions defined in claims 1 and 2, the waste heat of the combustible gas reforming process is utilized as the heat source required for catalyst regenerating heat in the catalyst regenerating apparatus or gas reforming reaction in the gas reforming apparatus, or the catalyst regenerating apparatus which uses the waste heat of the combustible gas reforming process is used. Therefore, a heat source having a low value such as the sensible heat of exhaust gas that is generated in a gasification process of a raw material can be used as the heat source for regenerating the catalyst or the heat source for gas reforming. Thus, since any external energy or the heat of combustion of the generated gas may be reduced or eliminated, the yield of the generated gas can be increased. As a result, the overall efficiency can be increased.

[0330] According to the inventions defined in claims 3 and 4, the char produced by gasifying the combustibles in the gasification apparatus is combusted in the char combustion apparatus, and the heat of combustion of the char is used as the heat source required for the catalyst regenerating heat or the gas reforming reaction in the gas reforming apparatus. Because any external energy or the heat of combustion of the generated gas may be reduced or eliminated, the yield of the generated gas can be increased. As a result, the overall efficiency can be increased.

[0331] According to the invention defined in claim 5, the gasification chamber and the combustion chamber each having a fluidized bed are integrated into a furnace. In addition to the effect of the invention of claim 4, the gasification apparatus has a function to gasify a raw material A and a function to combust char. Since char generated is combusted in the same apparatus, any trouble caused by the delivery of the char is avoided. Since the raw material is gasified in the fluidized bed and the char is combusted in the fluidized bed, the diffusion of heat is excellent, and stable operation can be performed.

[0332] According to the invention defined in claim 6, the gasification apparatus comprises a gasification apparatus having a fluidized bed which uses catalyst particles as at least part of a bed material, and at the same time that the combustibles are gasified to produce the generated gas in the gasification apparatus, the generated gas is reformed (tar decomposition) by bringing the generated gas and the catalyst particles as a bed material into contact with each other. Therefore, the generated gas is reformed efficiently. In addition to the effect of claims 3 and 4, gasification of the raw material and reforming of the gas, and combustion of the char and regeneration of the catalyst can be performed in one apparatus. Consequently, a catalyst regenerating apparatus can be eliminated, and the initial cost of the apparatus can be reduced.

[0333] According to the invention defined in claim 7, the gasification apparatus comprises a gasification chamber and a combustion chamber each having a fluidized bed which uses catalyst particles as at least part of a bed material, and at the same time that the combustibles are gasified into the generated gas in the gasification chamber, the generated gas is reformed by the catalyst particles, and the degraded catalyst particles are delivered to the combustion chamber, and heated and regenerated in the combustion chamber. Consequently, in addition to the effect of the invention of claim 6, the problem of handling of particles including char from the gasification chamber to the combustion chamber can be solved, and the heat efficiency is improved.

[0334] According to the invention defined in claim 8, inasmuch as the dust collecting and catalytic reaction apparatus having a dust collecting function and a gas reforming function dedusts the generated gas from the gasification apparatus before the generated gas is reformed (tar decomposition) by the catalyst, the catalyst is prevented from being degraded and from being mixed with dust. Further, separation of the catalyst is eliminated. In addition, the catalytic reaction apparatus may be of such a type as a reactor having a fixed bed which may possibly be clogged and may not be used in the presence of dust. Furthermore, the arrangement is suitable for preventing the catalyst, which decomposes tar at a low temperature, from being degraded or contaminated.

[0335] According to the invention defined in claim 9, since the catalyst degraded by reforming the generated gas is heated and regenerated by the catalyst regenerating apparatus with the heat of the combustion exhaust gas from the char combustion apparatus, in addition to the effect of the invention of claim 8, the catalyst can efficiently be regenerated or heated by the high-temperature heat of combustion of the char without using external energy or combusting part of the generated gas. It is thus possible to increase the yield of the generated gas. The overall amount of consumed energy is reduced, the running cost is low, and an LCA evaluation is high.

[0336] According to the invention defined in claim 10, since the gasification apparatus comprises a gasification chamber and a combustion chamber each having a fluidized bed, and the catalyst degraded by reforming the generated gas is heated and regenerated by the catalyst regenerating apparatus with the combustion exhaust gas from the combustion chamber, in addition to the effect of the invention of claim 9, the problem of handling of particles including char from the gasification chamber to the combustion chamber can be solved, a heat loss due to a heat radiation is reduced, and the heat efficiency is improved.

[0337] According to the invention defined in claim 11, since the gasification apparatus comprises a gasification chamber, a combustion chamber, and a dust collecting and catalyst reaction chamber each having a fluidized bed, in addition to the effect of the invention of claim 10, the problem of handling of particles including char from the dust collecting and catalyst reaction chamber to the combustion chamber can be solved, and the heat efficiency is improved. Because the dust collecting and catalyst reaction chamber is integrally combined with the gasification apparatus, the initial cost of the apparatus is lowered.

[0338] According to the invention defined in claim 12, since the catalyst degraded by reforming the generated gas in the dust collecting and catalyst reaction chamber is delivered to the combustion chamber, heated and regenerated in the combustion chamber, and then the regenerated catalyst is returned to the dust collecting and catalyst reaction chamber, in addition to the effect of the invention of claim 11, a catalyst regenerating apparatus can be eliminated. Therefore, the heat efficiency is improved and the initial cost of the apparatus is lowered.

[0339] According to the invention defined in claim 13, since the gas reforming apparatus and the catalyst regenerating apparatus comprise a fluidized-bed catalytic reaction apparatus which comprises a gas reforming chamber and a catalyst regeneration chamber each having a fluidized bed which uses catalyst particles as at least part of a bed material, the generated gas can efficiently be reformed by fluidization of catalyst particles, and catalyst particles degraded by reforming the generated gas can efficiently be heated and regenerated. A heat loss due to a heat radiation is reduced, and the heat efficiency is improved. In addition, the initial cost of the apparatus is lowered. Therefore, the overall amount of consumed energy is reduced, the running cost is low, and an LCA evaluation is high.

[0340] According to the invention defined in claim 14, because the gasification apparatus comprises a gasification chamber and a combustion chamber each having a fluidized bed, in addition to the effect of the invention of claim 13, the problem of handling of particles including char from the gasification chamber to the combustion chamber can be solved, and the heat efficiency is improved.

[0341] According to the invention defined in claim 15, because the gasification chamber, the combustion chamber, the gas reforming chamber, and the catalyst regeneration chamber are combined into a single furnace, in addition to the effect of claim 14, the heat efficiency is further improved. Further, the initial cost of the apparatus is further lowered.

[0342] According to the inventions defined in claims 16 and 17, a gas containing one or more of oxygen, steam, and hydrogen is supplied as a regenerating gas for regenerating the catalyst, and heat of reaction generated when the catalyst is regenerated and process waste heat are used to heat or regenerate catalyst particles. Therefore, a shortage of the process waste heat which uses the heat of combustion of part of the generated gas or the heat of reaction generated when the catalyst is regenerated can be supplemented with the heat of reaction, and hence the yield of the generated gas can further be improved.

[0343] According to the invention defined in claim 18, since the gasification apparatus is charged with an absorbent for absorbing chlorine compounds or sulfur compounds, the concentration of the chlorine compounds or the sulfur compounds can be reduced.

INDUSTRIAL APPLICABILITY

[0344] The present invention is applicable to a combustible gas reforming method and a combustible gas reforming apparatus for reforming a combustible gas which is produced by gasifying a combustible raw material such as coal, biomass, municipal wastes, industrial wastes, RDF (refuse-derived fuel), and waste plastics with a gasification apparatus.

Number	Date	Country	Kind
2001-299382	Sep 2001	JP
2001-380767	Dec 2001	JP

Process for reforming inflammable gas, apparatus for reforming inflammable gas and gasification apparatus

Information

Publication Number

Date Filed

Date Published

Inventors

CPC

US Classifications

International Classifications

Abstract

Description

Claims

Priority Claims (2)

PCT Information