Multi-ring Plasma Pyrolysis Chamber

Abstract

A pyrolysis chamber for the extraction of combustible gasses from biomass waste such as wood chips has a gravity fed chamber, where fuel passes, in succession, through a pre-heating zone, an oxidation and reduction zone, a gas outlet zone and a solids offloading zone. The pre-heating zone has plasma torches which direct an air plasma into the chamber, thereby pre-heating the fuel to a temperature of 1200-1500° C., after which the fuel enters the oxidation and reduction zone, where it is exposed to a steam plasma of 1500° C. which travels through plasma torches to an annular ring distributor surrounding the chamber and having apertures directing the steam plasma into the chamber, thereby providing enhanced generation of combustible gasses of CO and H 2 . The combustible gasses are removed in the gas outlet zone, which has a half annular ring collector removing combustible gasses out of the chamber and half annular ring distributor injecting an air plasma into the chamber for gasification of the ash residual carbon. A solids offloading part has a rotating grate for the removal of ash and slag for delivery to a water trough.

1 ) A pyrolysis chamber having a cylindrical body enclosing a volume, the cylindrical body having:
 a neck region for the introduction of fuel;   a pre-heating region below said neck region, said pre-heating region having at least one air plasma torch directing air plasma into said pre-heating region;   an oxidation and reduction region below said pre-heating region, said oxidation and reduction region including one or more steam plasma torches coupled to an annular ring distributor formed into said cylindrical body, said annular ring distributor having a plurality of apertures into said enclosed volume;   a gas outlet region below said oxidation and reduction region, said gas outlet region including a half annular ring distributor formed into said cylindrical body, said half annular ring distributor coupled to at least one air plasma torch, said half annular ring distributor having a plurality of apertures into said enclosed volume, said outlet region also having a half annular ring collector formed into said cylindrical body, said half annular ring collector having a plurality of apertures coupled to said enclosed volume and also having a gas outlet port for the removal of combustible gasses produced inside said enclosed volume;   a solids offloading zone below said unloading region for the removal of ash and slag, said solids offloading zone including a grate having apertures for the removal of ash and slag, said apertures coupled to a water filled trough, said water filled trough also enclosing a perimeter of said enclosure thereby forming an airtight seal.   
     
     
         2 ) The pyrolysis chamber of  claim 1  where said pre-heating air plasma torch has an arc length greater than 0.3 m. 
     
     
         3 ) The pyrolysis chamber of  claim 1  where said pre-heating air plasma torch generates an air plasma with a temperature greater than 2000° C. 
     
     
         4 ) The pyrolysis chamber of  claim 1  where said oxidizing and reduction steam plasma torch generates a steam plasma with a temperature greater than 1500° C. 
     
     
         5 ) The pyrolysis chamber of  claim 1  where said oxidation and reduction zone annular ring distributor is located within an inner and outer wall of said chamber. 
     
     
         6 ) The pyrolysis chamber of  claim 1  where said neck region including a hopper for controlling the introduction of said fuel. 
     
     
         7 ) The pyrolysis chamber of  claim 1  where said grate having apertures rotates below a stationary enclosure. 
     
     
         8 ) The pyrolysis chamber of  claim 1  where said ash and slag is removed from said trough. 
     
     
         9 ) The pyrolysis chamber of  claim 1  where said half annular ring distributor, said half annular ring collector, and said annular ring distributor are formed in said chamber wall and lined with refractory brick. 
     
     
         10 ) The pyrolysis chamber of  claim 1  where said plurality of apertures for at least one of said annular ring distributor, said half annular ring distributor, or said half annular ring collector are oriented downward into the volume of said chamber. 
     
     
         11 ) A process for extraction of combustible gasses from a fuel, the process having:
 a first step of loading fuel into a pre-heating zone, the pre-heating zone heated by a plurality of air plasma torches coupling air plasma into the chamber and thereby forming pre-heated fuel;   a second step of exposing said pre-heated fuel to a steam plasma generated by a steam plasma torch coupling the steam plasma into an annular ring distributor in the chamber and surrounding the pre-heated fuel, coupling the steam plasma in the annular ring distributor to the pre-heated fuel using a plurality of apertures, thereby reducing and oxidizing the pre-heated fuel and generating combustible gasses and waste products of ash and slag;   a third step of gasification by injecting an air plasma into the oxidized and reduced fuel with a half annular ring distributor having a plurality of apertures directing the combustion gasses into the outlet zone;   a fourth step of removing the combustible gasses by means of a half annular ring collector having a plurality of apertures connecting the chamber with the half annular ring collector directing the combustible gases to the external equipment for energy extraction;   a fifth step of removing ash and slag waste products by exposing the oxidized and reduced fuel to a rotating grate having apertures for removing ash and slag solids which have a grain size smaller than the apertures of the rotating grate, ash and slag solids which pass through the rotating grate thereafter coupled to a waste accumulation reservoir.   
     
     
         12 ) The process of  claim 11  where said pre-heating torch generates an air plasma with a temperature above 1500° C. 
     
     
         13 ) The process of  claim 11  where said steam plasma torch generates a steam plasma with a temperature above 1500° C. 
     
     
         14 ) The process of  claim 11  where said combustible gasses include CO and H 2 . 
     
     
         15 ) The process of  claim 11  where said air plasma and said steam plasma are adjusted for delivery volume to optimize for the generation of combustible gasses. 
     
     
         16 ) The process of  claim 11  where at least one of said air plasma or said steam plasma includes a post-plasma air introduction to regulate the plasma temperature to a desired range. 
     
     
         17 ) The process of  claim 11  where at least one of said third step annular ring apertures or said fourth step annular ring apertures are directed downward. 
     
     
         18 ) An apparatus for pyrolysis having:
 an enclosed chamber;   a fuel introduction zone for the introduction of fuel at the top of said chamber;   a pre-heating zone below said fuel introduction zone for the introduction of air plasma into introduced fuel, thereby forming pre-heated fuel;   an oxidation and reduction zone below said pre-heating zone, said oxidation and reduction zone having an annular ring distributor formed into the walls of said enclosed chamber, said annular ring distributor coupled to said enclosed volume through a plurality of apertures, said annular ring distributor coupled to one or more plasma torches generating a steam plasma coupled into said annular ring distributor, each said plasma torch fed with a source of steam;   a gas outlet zone below said oxidation and reduction zone, said gas outlet zone having a half annular distribution ring with a plurality of apertures coupled into said enclosed chamber on one half of said enclosed chamber said half annular distribution ring coupled to one or more air plasma torches, said gas outlet zone also having a half annular collection ring with a plurality of apertures coupled into said enclosed chamber on an opposite half of said enclosed chamber from said half annular distribution ring, said half annular collection ring coupled to a gas outlet;   a solid waste offloading zone below said gas outlet zone, said solid waste offloading zone adjacent to a grate with apertures for the removal of ash and slag from the fuel of said oxidation and reduction zone.   
     
     
         19 ) The apparatus of  claim 18  where at least one of:
 said oxidation and reduction annular ring distributor; 
 said gas outlet zone annular ring collector; 
 said gas outlet zone annular ring distributor; 
 is formed into the walls of said enclosed volume. 
 
     
     
         20 ) The apparatus of  claim 18  where at least one of:
 said oxidation and reduction annular ring distributor apertures; 
 said gas outlet zone annular ring collector apertures; 
 said gas outlet zone annular ring distributor apertures; 
 are disposed about the inner wall of said enclosed chamber, said apertures directed downward toward said solid waste offloading zone.