System and method for converting solids into fuel

Abstract

A system for converting a solid fuel into a fuel including a pyrolytic unit for producing a pyro gas comprising hydrocarbons, a synthesis gas production unit for converting the pyro gas into a synthesis gas comprising a mixture of hydrogen and carbon monoxide, and a gas-to-liquid unit for converting the synthesis gas into a fuel.

1 . A method for converting a solid fuel into a fuel product, comprising:
 gasifying in a retort comprising one or more augers a solid fuel into a pyro gas comprising less than about 15% carbon dioxide, the gasifying being conducted at about 800° F. to about 1300° F., and wherein the solid fuel is gasifying while the one or more augers move it through the retort;   reforming the pyro gas into a synthetic gas; and   converting the synthetic gas into a fuel product.   
     
     
         2 . The method of  claim 1 , wherein the gasifying is conducted without introduction of an oxygen, air, or steam stream. 
     
     
         3 . The method of  claim 1 , wherein the retort is sealed and equipped with air tight inlet and outlet valves configured to prevent introduction of air into the reactor during operation. 
     
     
         4 . The method of  claim 1 , wherein the solid fuel comprises municipal solid waste, municipal sludge, biosolid, rubber, plastic, coal, organic waste, inorganic waste, medical waste, by-products thereof, or combinations thereof. 
     
     
         5 . The method of  claim 1 , further comprising removing pollutants from the pyro gas. 
     
     
         6 . The method of  claim 1 , further comprising removing pollutants from the synthetic gas to form a processed synthetic gas. 
     
     
         7 . The method of  claim 1 , wherein the fuel product is a wax, liquid, a gas, or a combination thereof. 
     
     
         8 . The method of  claim 7 , wherein the liquid comprises diesel, gasoline, jet fuels, alcohols, or mixtures thereof. 
     
     
         9 . The method of  claim 1 , wherein gasifying the solid fuel comprises continuous indirect flame pyrolysis. 
     
     
         10 . The method of  claim 1 , wherein reforming the pyro gas comprises steam reforming the pyro gas. 
     
     
         11 . The method of  claim 1 , wherein converting the synthetic gas comprises using a Fischer-Tropsch reaction. 
     
     
         12 . The method of  claim 1 , further comprising pre-treating the solid fuel. 
     
     
         13 . The method of  claim 1 , wherein the pyro gas comprises from about 1% to about 15% carbon dioxide. 
     
     
         14 . The method of  claim 1 , wherein converting the synthetic gas into the fuel comprises reacting the synthetic gas with a catalyst to form a liquid fuel. 
     
     
         15 . The method of  claim 1 , further comprising controlling a speed of the one or more augers so that a travel time of the solid fuel through the retort is approximately one hour. 
     
     
         16 . The method of  claim 1 , wherein the gasifying is conducted at a negative atmospheric pressure. 
     
     
         17 . A method of gasifying a solid fuel, comprising:
 gasifying in a retort comprising one or more augers a solid fuel into a pyro gas comprising less than about 15% carbon dioxide, the gasifying being conducted without introduction of an oxygen, air, or steam stream at about 800° F. to about 1300° F. and at a negative atmospheric pressure, wherein the retort is sealed and equipped with air tight inlet and outlet valves configured to prevent introduction of air into the reactor during operation, and wherein the solid fuel is gasifying while the one or more augers move it through the retort.   
     
     
         18 . The method of  claim 17 , wherein the solid fuel comprises municipal solid waste, municipal sludge, biosolid, rubber, plastic, coal, organic waste, inorganic waste, medical waste, by-products thereof, or combinations thereof. 
     
     
         19 . The method of  claim 17 , further comprising controlling a speed of the one or more augers so that a travel time of the solid fuel through the retort is approximately one hour. 
     
     
         20 . A method of generating energy, comprising:
 gasifying in a retort comprising one or more augers a solid fuel into a pyro gas comprising less than about 15% carbon dioxide, the gasifying being conducted without introduction of an oxygen, air, or steam stream at about 800° F. to about 1300° F. and at a negative atmospheric pressure, wherein the retort is sealed and equipped with air tight inlet and outlet valves configured to prevent introduction of air into the reactor during operation, and wherein the solid fuel is gasifying while the one or more augers move it through the retort; and   combusting the pyro gas to generate energy.