System And Method For Thermal Conversion Of Carbon Based Materials

Abstract

The present invention relates to a system for thermal conversion of carbon based materials into combustible oil and/or gas. More specifically, said system comprises: a first fluid bed reactor, a second vapour wash reactor, a third fractionation reactor, a fourth moving bed reactor, a fifth fluid bed reactor and a sixth gasification reactor.

1 . System for the thermal conversion of carbon based materials into combustible oil and/or gas comprising:
 a first fluid bed reactor for thermal cracking of carbon based materials, the first fluid bed reactor comprising at least one intake, the at least one intake comprising at least one inlet for receiving carbon based materials, at least one inlet for receiving processed solid materials, and at least one inlet for receiving solids and oil, at least one discharge end, the at least one discharge end comprising at least one outlet for carbon comprising solid material, at least one outlet for metals and minerals, and at least one outlet for effluent vapor and gas;   a second vapor wash reactor connected to the outlet for effluent vapor and gas for washing effluent vapor and gas from the first fluid bed reactor, the second vapor wash reactor comprising at least one intake, the at least one intake comprising at least one inlet for receiving the effluent vapor gas, and at least one discharge end, the at least one discharge end comprising at least one outlet for washed vapor and gas, and at least one outlet for solids and oil connected to the inlet for solids and oil of the first fluid bed reactor for reintroducing the solids and oil into the first fluid bed reactor;   a third reactor connected to the outlet for washed vapor and gas for fractioning of the vapor and gas, the third reactor comprising at least one intake, the at least one intake comprising at least one inlet for receiving the washed vapor and gas, at least one discharge end, the at least one discharge end comprising at least one outlet for combustible oil, and at least one outlet for non-condensed gas;   a fourth moving bed reactor connected to the at least one outlet for carbon comprising solid material for stabilizing carbon in the solid material through conversion of gaseous materials, the fourth moving bed reactor comprising at least one intake, the at least one intake comprises at least one inlet for receiving the carbon comprising solid material, and at least one discharge end, the at least one discharge end comprising at least one outlet for stabilized carbon comprising solid material;   a fifth fluid bed reactor connected to the at least one outlet for stabilized carbon comprising solid material, the fifth fluid bed reactor comprising at least one intake, the at least one intake comprising at least one inlet for receiving the stabilized carbon comprising solid material, and at least one inlet for receiving processed gas from a sixth reactor, at least one discharge end, the at least one discharge end comprising at least one outlet connected with the at least one inlet for receiving processed carbon comprising solid material for reintroducing processed solid materials into the first fluid bed reactor, and at least one outlet for gas; and   a sixth reactor connected to at least one outlet for non-condensed gas for gasification of non-condensed gas from the third reactor, the sixth reactor comprising at least one intake, the at least one intake comprising at least inlet for receiving the non-condensed gas, and at least one discharge end, the at least one discharge end comprising at least one outlet for transporting processed gas to the at least one inlet for receiving processed gas.   
     
     
         2 . The system according to  claim 1 , wherein the first fluid bed reactor is connected through the at least one inlet for receiving the carbon based materials with a dryer, the dryer comprising at least one inlet for receiving solid carbon based materials, at least one outlet for transporting dried solid carbon based materials into the first fluid bed reactor, and at least one outlet for discharging non-carbon based material. 
     
     
         3 . The system according to  claim 1 , wherein the first fluid bed reactor is connected through the at least one inlet for receiving the carbon based materials with a homogenizer, the homogenizer comprising at least one inlet for receiving liquid carbon based materials, and at least one outlet for transporting homogenized liquid carbon based materials into the first fluid bed reactor. 
     
     
         4 . The system according to  claim 1 , wherein the fifth reactor is connected through the at least one outlet for gas with a gasfilter, the gasfilter comprising at least one inlet for receiving gas, and at least one outlet for discharging combustible gas. 
     
     
         5 .- 6 . (canceled) 
     
     
         7 . The system according to  claim 1  further comprising an oxygen membrane between the third reactor and the sixth reactor for oxygenation and/or oxidation of the non-condensed gas. 
     
     
         8 . The system according to  claim 4 , wherein the gas from the outlet for gas of the fifth fluid bed reactor is transported to the gasfilter through one or both the fourth moving bed reactor and the first fluid bed reactor. 
     
     
         9 . The system according to  claim 1 , wherein the carbon based materials are selected from the group consisting of biomass, wood, forestry waste products, organic waste, agricultural waste products, plastics and tires. 
     
     
         10 . Method for the thermal conversion of carbon based materials into combustible oil and/or gas comprising introducing carbon based materials into the system according to  claim 1 . 
     
     
         11 . The method according to  claim 10 , wherein the residence time in the first fluid bed reactor is in the range of approximately 30 to 90 minutes, the residence time in the second vapor wash reactor is in the range of approximately 0.5 to 5 seconds, the residence time in the third reactor is in the range of approximately 1 to 5 seconds, the residence time in the fourth moving bed reactor is in the range of approximately 180 to 240 minutes, the residence time in the fifth fluid bed reactor is in the range of approximately 30 to 120 minutes, and the residence time in the sixth reactor is in the range of approximately 1 to 5 seconds. 
     
     
         12 . (canceled) 
     
     
         13 . The system of  claim 1 , wherein first fluid bed reactor operates in a temperature range of approximately 350° C. to 450° C., a hydrogen pressure range of approximately 200 to 300 mbar, and an oxygen pressure range of approximately 10 −5  to 10 −9  mbar;
 the second vapor wash reactor operates in a temperature range of approximately 150° C. to 300° C., a hydrogen pressure range of approximately 200 to 300 mbar, and an oxygen pressure range of approximately 10 −5  to 10 −9  mbar; 
 the third reactor operates in a temperature range of approximately 30° C. to 80° C., a hydrogen pressure range of approximately 200 to 300 mbar, and an oxygen pressure range of approximately 10 −5  to 10 −9  mbar; 
 the fourth moving bed reactor operates in a temperature range of approximately 550° C. to 650° C., a hydrogen pressure range of approximately 200 to 300 mbar, and an oxygen pressure range of approximately 10 −5  to 10 −9  mbar; 
 the fifth fluid bed reactor operates in a temperature range of approximately 700° C. to 850° C., a hydrogen pressure range of approximately 200 to 300 mbar, and an oxygen pressure range of approximately 10 −5  to 10 −9  mbar; 
 the sixth reactor operates in a temperature range of approximately 1100° C. to 1300° C., a hydrogen pressure range of approximately 200 to 300 mbar, and an oxygen pressure range of approximately 10 −2  to 10 −5  mbar; and 
 wherein the carbon comprising solid material from the first fluid bed reactor is reintroduced into the first fluid bed after been processed in the fourth, fifth and sixth reactors. 
 
     
     
         14 . Method for the thermal conversion of carbon based materials into combustible oil and/or gas comprising:
 operating a first fluid bed reactor in a temperature range of approximately 350° C. to 450° C., a hydrogen pressure range of approximately 200 to 300 mbar, and an oxygen pressure range of approximately 10 −5  to 10 −9  mbar, the first fluid bed reactor for thermal cracking of carbon based materials, the first fluid bed reactor comprising at least one intake, the at least one intake comprising at least one inlet for receiving carbon based materials, at least one inlet for receiving processed solid materials, and at least one inlet for receiving solids and oil, at least one discharge end, the at least one discharge end comprising at least one outlet for carbon comprising solid material, at least one outlet for metals and minerals, and at least one outlet for effluent vapor and gas;   operating a second vapor wash reactor in a temperature range of approximately 150° C. to 300° C., a hydrogen pressure range of approximately 200 to 300 mbar, and an oxygen pressure range of approximately 10 −5  to 10 −9  mbar, the second vapor wash reactor connected to the outlet for effluent vapor and gas for washing effluent vapor and gas from the first fluid bed reactor, the second vapor wash reactor comprising at least one intake, the at least one intake comprising at least one inlet for receiving the effluent vapor gas, and at least one discharge end, the at least one discharge end comprising at least one outlet for washed vapor and gas, and at least one outlet for solids and oil connected to the inlet for solids and oil of the first fluid bed reactor for reintroducing the solids and oil into the first fluid bed reactor;   operating a third reactor in a temperature range of approximately 30° C. to 80° C., a hydrogen pressure range of approximately 200 to 300 mbar, and an oxygen pressure range of approximately 10 −5  to 10 −9  mbar, the third reactor connected to the outlet for washed vapor and gas for fractioning of the vapor and gas, the third reactor comprising at least one intake, the at least one intake comprising at least one inlet for receiving the washed vapor and gas, at least one discharge end, the at least one discharge end comprising at least one outlet for combustible oil, and at least one outlet for non-condensed gas;   operating a fourth moving bed reactor in a temperature range of approximately 550° C. to 650° C., a hydrogen pressure range of approximately 200 to 300 mbar, and an oxygen pressure range of approximately 10 −5  to 10 −9  mbar, the fourth moving bed reactor connected to the at least one outlet for carbon comprising solid material for stabilizing carbon in the solid material through conversion of gaseous materials, the fourth moving bed reactor comprising at least one intake, the at least one intake comprises at least one inlet for receiving said the carbon comprising solid material, and at least one discharge end, the at least one discharge end comprising at least one outlet for stabilized carbon comprising solid material;   operating a fifth fluid bed reactor in a temperature range of approximately 700° C. to 850° C., a hydrogen pressure range of approximately 200 to 300 mbar, and an oxygen pressure range of approximately 10 −5  to 10 −9  mbar, the fifth fluid bed reactor connected to the at least one outlet for stabilized carbon comprising solid material, the fifth fluid bed reactor comprising at least one intake, the at least one intake comprising at least one inlet for receiving the stabilized carbon comprising solid material, and at least one inlet for receiving processed gas from a sixth reactor, at least one discharge end, the at least one discharge end comprising at least one outlet connected with the at least one inlet for receiving processed carbon comprising solid material for reintroducing processed solid materials into the first fluid bed reactor, and at least one outlet for gas; and   operating a sixth reactor in a temperature range of approximately 1100° C. to 1300° C., a hydrogen pressure range of approximately 200 to 300 mbar, and an oxygen pressure range of approximately 10 −2  to 10 −5  mbar, the sixth reactor connected to at least one outlet for non-condensed gas for gasification of non-condensed gas from the third reactor, the sixth reactor comprising at least one intake, the at least one intake comprising at least inlet for receiving the non-condensed gas, and at least one discharge end, the at least one discharge end comprising at least one outlet for transporting processed gas to the at least one inlet for receiving processed gas.   
     
     
         15 . The method according to  claim 14  further comprising operating at least one reactor with a residence time according to the following:
 if the first fluid bed reactor, a residence time in the range of approximately 30 to 90 minutes; 
 if the second vapor wash reactor, a residence time in the range of approximately 0.5 to 5 seconds; 
 if the third reactor, a residence time in the range of approximately 1 to 5 seconds; 
 if the fourth moving bed reactor, a residence time in the range of approximately 180 to 240 minutes; 
 if the fifth fluid bed reactor, a residence time in the range of approximately 30 to 120 minutes; or 
 if the sixth reactor, a residence time in the range of approximately 1 to 5 seconds. 
 
     
     
         16 . The method according to  claim 14  further comprising operating each reactor with a residence time according to the following:
 the first fluid bed reactor, a residence time in the range of approximately 30 to 90 minutes; 
 the second vapor wash reactor, a residence time in the range of approximately 0.5 to 5 seconds; 
 the third reactor, a residence time in the range of approximately 1 to 5 seconds; 
 the fourth moving bed reactor, a residence time in the range of approximately 180 to 240 minutes; 
 the fifth fluid bed reactor, a residence time in the range of approximately 30 to 120 minutes; and 
 the sixth reactor, a residence time in the range of approximately 1 to 5 seconds. 
 
     
     
         17 . The method according to  claim 14  further comprising homogenizing liquid carbon based materials, wherein the first fluid bed reactor is connected through the at least one inlet for receiving the carbon based materials with a homogenizer, the homogenizer comprising at least one inlet for receiving liquid carbon based materials, and at least one outlet for transporting the homogenized liquid carbon based materials into the first fluid bed reactor. 
     
     
         18 . The method according to  claim 14  further comprising transporting solid material between one or more of the reactors by fluming. 
     
     
         19 . The method according to  claim 14  further comprising operating one or more of the reactors at a pressure higher than atmospheric pressure. 
     
     
         20 . The method according to  claim 14  further comprising:
 drying solid carbon based materials; and 
 introducing the dried solid carbon based materials into the first fluid bed reactor; 
 wherein the first fluid bed reactor is connected through the at least one inlet for receiving the carbon based materials with a dryer, the dryer comprising at least one inlet for receiving solid carbon based materials, at least one outlet for transporting the dried solid carbon based materials into the first fluid bed reactor, and at least one outlet for discharging non-carbon based material. 
 
     
     
         21 . The method according to  claim 14  further comprising discharging combustible gas, wherein the fifth reactor is connected through the at least one outlet for gas with a gasfilter, the gasfilter comprising at least one inlet for receiving gas, and at least one outlet for discharging the combustible gas. 
     
     
         22 . The method according to  claim 14  further comprising oxygenation and/or oxidation of non-condensed gas, wherein an oxygen membrane is provided between the third reactor and the sixth reactor for the oxygenation and/or oxidation of the non-condensed gas. 
     
     
         23 . The method according to  claim 14 , wherein the carbon based materials are selected from the group consisting of biomass, wood, forestry waste products, organic waste, agricultural waste products, plastics and tires. 
     
     
         24 . Method for the thermal conversion of carbon based materials into combustible oil and/or gas, wherein
 the carbon based materials are thermally cracked in a first fluid bed reactor, to yield effluent vapor and gas and carbon comprising solid material;   the effluent vapor and gas are washed to yield washed vapor and gas, and solids and oil, said solids and oil being reintroduced into the first fluid bed reactor;   the washed vapor and gas are fractionated to yield non-condensed gas and a combustible oil;   the carbon comprising solid material is passed to a moving bed reactor, operated at a temperature of 550° C. to 650° C. to yield stabilized carbon comprising solid material;   the non-condensed gas is gasified to yield processed gas; and   the stabilized carbon comprising solid material and processed gas is passed to a fifth fluid bed reactor to gasify the stabilized carbon comprising solid material yielding gas and carbon comprising solid material; and   the carbon comprising solid material is reintroduced into said first fluid bed reactor.