System and method for reutilizing co2 from combusted carbonaceous material

Abstract

A system for generating steam supplies of coal another material to one or more processing chambers. Each processing chamber includes a plasma arc torch that heats the material in the presence of water and a treatment gas at an extremely high temperature. A product gas stream is delivered from each processing chamber to a heat recovery steam generator (HRSG). Each HRSG generates steam that is used to drive a steam turbine. The processing chambers and HRSGs are fluidly connected so that the product gas streams moves from a processing chamber, to a HRSG, to another processing chamber, and then to another HRSG, etc. Within any of the HRSGs, or after the final HRSG, water in the product gas may condense to liquid water that may be redirected to any of the processing chambers. In addition, CO 2 from the final HRSG may be redirected into any of the processing chambers to facilitate further reactions in the chambers.

1 . A system for generating steam comprising:
 a primary processing chamber comprising at least one plasma arc torch that heats at least a portion of the primary processing chamber to a temperature of from about 5540° C. to 11,080° C.;   a feed source configured to deliver a carbonaceous material feed to the primary processing chamber;   a first treatment gas source configured to deliver a treatment gas to the primary processing chamber;   a first water source configured to deliver water to the primary processing chamber;   a first heat recovery steam generator that is fluidly connected to the primary processing chamber and configured to receive a product gas stream comprising at least water vapor from the primary processing chamber;   a scrubber configured to receive and process the product gas stream;   a first programmable valve having a first control mechanism configured to selectively direct a portion of the carbon dioxide in the product gas stream back to the primary processing chamber and a portion of the carbon dioxide to a baghouse; and   a second programmable valve having a second control mechanism configured to selectively direct a portion of the water back to the primary processing chamber and a portion of the water to a water facility, wherein the water is condensed from the product gas stream.   
     
     
         2 . The system of  claim 1  further comprising:
 a secondary processing chamber configured to receive the product gas stream from the first heat recovery steam generator, the secondary processing chamber comprising at least one plasma arc torch that heats at least a portion of the secondary processing chamber to a temperature of from about 5540° C. to 11,080° C.; 
 a second treatment gas source configured to deliver a treatment gas to the secondary processing chamber; 
 a second water source configured to deliver water to the secondary processing chamber; and 
 a second heat recovery steam generator that is fluidly connected to the secondary processing chamber and configured to receive a product gas stream from the second processing chamber and deliver the product gas stream to the scrubber. 
 
     
     
         3 . The system of  claim 2  further comprising:
 a steam turbine configured to receive steam that is generated by the first heat recovery steam generator and by the second heat recovery steam generator. 
 
     
     
         4 . The system of  claim 2  further comprising:
 an automated control system, the automated control system comprising:
 a) a plurality of monitors each configured to measure a process parameter and provide data thereof; 
 b) a processor in data communication with the plurality of monitors; and 
 c) at least two actuation mechanisms in data communication with the processor; 
 
 wherein the first of the at least two actuation mechanisms is in operative communication with the first control mechanism of the first programmable valve, and the second of the a least two actuation mechanisms is in operative communication the second control mechanism of the second programmable valve. 
 
     
     
         5 . The system of  claim 4 :
 wherein the data provided by each of the plurality of monitors comprises at least one of temperature, pressure, carbon dioxide composition, water volume, and gas flow.   
     
     
         6 . The system of  claim 5 :
 wherein at least one of the plurality of monitors provides a first pressure data associated with the primary processing chamber; at least one of the plurality of monitors provides a carbon dioxide composition data associated with the product gas stream from the primary processing chamber; and   wherein the first of the at least two actuation mechanisms is controlled at least in part by the processor based on at least one of the carbon dioxide composition data, and the pressure data.   
     
     
         7 . The system of  claim 5 :
 wherein at least one of the plurality of monitors provides a first water volume data associated with the water delivered by the first water source; at least one of the plurality of monitors provides a second water volume data associated with the water delivered by the second water source, and at least one of the plurality of monitors provides temperature data associated with the primary processing chamber; and   wherein the second of the at least two actuation mechanisms is controlled at least in part by the processor based on at least one of the first water volume data, the second water volume data, and the temperature data.   
     
     
         8 . The system of  claim 7 :
 wherein the water is condensed from the product gas stream in the wet scrubber.   
     
     
         9 . The system of  claim 7 :
 wherein the water is condensed from the product gas stream in either the first heat recovery steam generator or the second heat recovery steam generator.   
     
     
         10 . A method for generating steam comprising:
 providing a continuous supply of a carbonaceous material;   combusting the carbonaceous material in a first processing chamber having a first plasma arc torch in the presence of a first treatment gas and water to provide a first product gas stream, the first product gas stream comprising at least water and carbon dioxide;   recovering heat from the first product gas stream in a first heat recovery steam generator to produce a first steam output;   processing the first product gas stream in a second processing chamber having a second plasma arc torch in the presence of a second treatment gas and water to provide a second product gas stream comprising at least carbon dioxide and substantially free of carbon monoxide and hydrogen;   recovering heat from the second product gas stream in a second heat recovery steam generator to produce a second steam output;   directing at least a portion of the carbon dioxide to the first processing chamber; and,   directing at least a portion of the water to the first processing chamber;   wherein each of the first plasma torch and the second plasma torch generates heat from 5540 C to 11,080 C;   wherein the carbon dioxide is directed to the first processing chamber via a first programmable valve having a first control mechanism; and,   wherein the water is directed to the first processing chamber via a second programmable valve having a second control mechanism.   
     
     
         11 . The method of  claim 10  further comprising:
 processing the second stream output in a wet scrubber to provide a wet scrubber output. 
 
     
     
         12 . The method of  claim 11 :
 wherein the wet scrubber output comprises at least water and carbon dioxide.   
     
     
         13 . The method of  claim 11  further comprising:
 providing a plurality of monitors each configured to measure at least one of a plurality of process parameters and provide data thereof to a processor; and 
 controlling the first control mechanism and the second control mechanism by the processor, based at least in part on the data provided by the plurality of monitors. 
 
     
     
         14 . The method of  claim 13 :
 wherein the plurality of process parameters measured by the monitors comprise at least one of temperature, pressure, carbon dioxide composition, water volume, and gas flow.   
     
     
         15 . The method of  claim 13 :
 wherein the plurality of monitors measure the process parameters in at least one of the first processing chamber, the first product gas stream, the first heat recovery steam generator, the first steam output, the second processing chamber, the second product gas stream, and the second stream output.