Gasification apparatus and method

Abstract

A gasification system is disclosed having a combustion or reaction vessel, a scrubber housing, and a filter housing. A carbonaceous fuel is partially combusted in the reaction vessel to generate a combustible gas. An improved ash support and removal system reduces clogging and other problems in the reaction vessel. The combustible gas passes through the scrubber housing to remove matter such as tar and oil, and the scrubbed gas passes through a hybrid blower to the filter housing. Wood chips are used in the filter housing to provide a relatively clean, dry gas. Wastewater and other waste products from the scrubber housing and filter housing are captured and returned to the reaction vessel.

1 . A method, comprising: 
 (1) at least partially combusting a carbonaceous fuel to produce a combustible gas;    (2) passing said combustible gas through sprayed water to produce a scrubbed gas;    (3) passing said scrubbed gas through wood chips; and    (4) after step (3), combusting said scrubbed gas.    
     
     
         2 . The method of  claim 1 , wherein step (1) comprises: 
 at least partially combusting said carbonaceous fuel to produce said combustible gas, said carbonaceous fuel comprising chicken litter.    
     
     
         3 . The method of  claim 1 , wherein step (1) comprises: 
 at least partially combusting said carbonaceous fuel to produce said combustible gas, said carbonaceous fuel comprising wood pulp sludge.    
     
     
         4 . The method of  claim 1 , wherein: 
 step (1) comprises at least partially combusting said carbonaceous fuel in a reaction vessel to produce said combustible gas; and    step (2) comprises passing said combustible gas through said sprayed water in a scrubber housing to produce said scrubbed gas; and further comprising    passing wastewater from said scrubber housing to said reaction vessel.    
     
     
         5 . The method of  claim 1 , wherein: 
 step (1) comprises at least partially combusting said carbonaceous fuel in a reaction vessel to produce said combustible gas; and    step (3) comprises passing said scrubbed gas through said wood chips in a filter housing;    and further comprising    passing wastewater from said filter housing to said reaction vessel.    
     
     
         6 . The method of  claim 4 , wherein: 
 step (3) comprises passing said scrubbed gas through said wood chips in a filter housing;    and further comprising:    passing wastewater from said filter housing to said reaction vessel.    
     
     
         7 . The method of  claim 1 , wherein: 
 step (1) comprises at least partially combusting said carbonaceous fuel in a reaction vessel to produce said combustible gas;    step (2) comprises passing said combustible gas through said sprayed water in a scrubber housing to produce said scrubbed gas; and    step (3) comprises passing said scrubbed gas through said wood chips in a filter housing;    and further comprising:    passing wastewater from said scrubber housing to a recycle tank;    passing wastewater from said filter housing to said recycle tank; and    passing said wastewater from said scrubber housing and said wastewater from said filter housing from said recycle tank to said reaction vessel.    
     
     
         8 . A method, comprising: 
 (1) at least partially combusting a carbonaceous fuel in a reactor vessel to produce a combustible gas;    (2) passing said combustible gas to a scrubber housing;    (3) spraying a liquid on said combustible gas within said scrubber housing; and    (4) passing a first portion of said liquid from said scrubber housing to said reactor vessel.    
     
     
         9 . The method of  claim 8 , wherein step (3) comprises: 
 spraying said liquid on said combustible gas within said scrubber housing, said liquid comprising water.    
     
     
         10 . The method of  claim 8 , wherein step (3) comprises: 
 spraying said liquid on said combustible gas within said scrubber housing to remove matter from said combustible gas, said matter comprising tar and oil; and further comprising:    passing said tar and oil from said scrubber housing to said reactor vessel.    
     
     
         11 . The method of  claim 8 , further comprising: 
 passing said combustible gas from said scrubber housing to a filter housing; and    passing a waste liquid from said filter housing to said reaction vessel.    
     
     
         12 . The method of  claim 8 , wherein step (4) comprises: 
 passing said first portion of said liquid from said scrubber housing to a recycle housing; and    passing said first portion of said liquid from said recycle housing to said reaction vessel.    
     
     
         13 . The method of  claim 12 , wherein step (3) comprises: 
 spraying said liquid on said combustible gas within said scrubber housing to remove matter from said combustible gas, said matter comprising tar and oil; and further comprising:    passing said tar and oil from said scrubber housing to said recycle housing; and    passing said tar and oil from said recycle housing to said reactor vessel.    
     
     
         14 . The method of  claim 13 , further comprising: 
 passing said combustible gas from said scrubber housing to a filter housing;    passing waste liquid from said filter housing to said recycle housing; and    passing said waste liquid from said recycle housing to said reaction vessel.    
     
     
         15 . A combination, comprising: 
 a reaction vessel having an upper outer wall portion and a lower base portion;    an inner wall disposed within said vessel, an upper portion of said inner wall being connected to said vessel to form an inner chamber and an outer chamber, a lower portion of said inner wall defining a first opening within said vessel;    an ash support member disposed within said vessel below said first opening, said ash support member being affixed within said vessel so that ash may spill from said ash support member over at least approximately 80 percent of an outer periphery of said ash support member.    
     
     
         16 . The combination of  claim 15 , wherein said ash support member is affixed within said vessel so that ash may spill from said ash support member over at least approximately 90 percent of said outer periphery of said ash support member.  
     
     
         17 . The combination of  claim 15 , further comprising: 
 a first agitating member disposed within said reaction vessel above said opening; and    a second agitating member disposed within said reaction vessel below said opening.    
     
     
         18 . The combination of  claim 15 , further comprising: 
 a scrubber housing, said scrubber housing being operably connected to said reaction vessel to provide a flow path from said outer chamber of said reaction vessel to said scrubber housing;    a filter housing, said filter housing being operably connected to said scrubber housing; and    wood chips disposed in said filter housing.    
     
     
         19 . The combination of  claim 15 , further comprising: 
 a blower disposed downstream from said reaction vessel and operably connected to said reaction vessel for withdrawing a combustible gas from said reaction vessel, said blower comprising:    an impeller housing;    an impeller disposed within said impeller housing; and    an O-ring, said O-ring disposed to provide a seal between portions of said impeller housing.    
     
     
         20 . The combination of  claim 19 , said blower further comprises: 
 a shaft affixed to said impeller; and    at least three sets of bearings operably connected to said shaft.