Melt gasifier system

Abstract

A method to perform gasification in a gasification reactor is having a molten metal material disposed within a refractory lined vessel of the gasification reactor for converting a feed into product syngas by contacting feed into melt. A melt is formed by inductive melting by one or more induction coil apparatuses. A feed is injected into contact with the melt to dissolve at least a portion of the feed into the melt. A refractory-lined vessel is tilted at a pre-determined tilt angle about a horizontal plane to cause the refractory-lined vessel to be tilted at said pre-determined tilt angle from said horizontal plane during a conversion of the feed into a product syngas. A molten slag material is directed to flow away from the refractory-lined vessel at a pre determined molten slag material flow rate and product syngas is directed to flow from the refractory-lined vessel to a powerplant for electric power generation, a first chemical catalytic reactor to chemically reform product syngas into a determined hydrocarbon product, a second chemical catalytic reactor to chemically reform product syngas into anhydrous ammonia product, a third chemical catalytic reactor to chemically reform product syngas into methanol product, or a combination thereof.

1 . A method to perform gasification in a gasification reactor having a molten metal material disposed within a refractory lined vessel of the gasification reactor for converting a feed into product syngas by contacting feed into melt, comprising
 forming a melt by inductive melting by one or more induction coil apparatuses energized with one or more alternating current “AC” power waveforms;   injecting a feed into contact with the melt to dissolve at least a portion of the feed into the melt, wherein the feed is selected from coal, lignite, coal-liquid slurry, wood, biomass, municipal solid waste, sewage, crude oil, natural gas, petroleum residue, bituminous sand, seawater, shale oil material, peat, or a combination thereof;   tilting and positioning a refractory-lined vessel at a pre-determined tilt angle about a horizontal plane to cause the refractory-lined vessel to be tilted at said pre-determined tilt angle from said horizontal plane during a conversion of the feed into a product syngas;   directing molten slag material formed during conversion of the feed into product syngas to flow away from the refractory-lined vessel at a pre-determined molten slag material flow rate;   directing product syngas to flow from the refractory-lined vessel to a powerplant for electric power generation, a first chemical catalytic reactor to chemically reform product syngas into a determined hydrocarbon product, a second chemical catalytic reactor to chemically reform product syngas into anhydrous ammonia product, a third chemical catalytic reactor to chemically reform product syngas into methanol product, or a combination thereof.   
     
     
         2 . Method to perform gasification according to  claim 1 , wherein the pre-determined tilt angle is between 0 to 60 degrees. 
     
     
         3 . Method to perform gasification according to  claim 1 , comprising directing product syngas to flow through a steam generator device to transfer heat from said product syngas to the steam generator device to cause generation of steam. 
     
     
         4 . Method according to  claim 1 , wherein an oxygen-carrying gas is directed into the gasifier during gasification of the feed at a superficial gas velocity of at least about 10 meters per second. 
     
     
         5 . Method according to  claim 4 , wherein the oxygen-carrying gas is selected from air, oxygen, carbon dioxide, or a combination thereof. 
     
     
         6 . Gasification reactor for converting a feed into product syngas by contacting feed into a melt, the melt being disposed within the gasification reactor, the gasification reactor comprising
 a refractory-lined vessel in operational communication with gasification reactor for holding the melt,   an induction coil apparatus for inductively heating the melt during a conversion of the feed into product syngas,   injection means for injecting a feed into contact with the melt to dissolve at least a portion of the feed into the melt,   tilting and positioning means for tilting and positioning the refractory-lined vessel at a pre-determined tilt angle about a horizontal plane to cause the refractory-lined vessel to be tilted at the pre-determined tilt angle with respect to the horizontal plane during a conversion of the feed into a product syngas;   a slag conduit for directing molten slag material formed during conversion of the feed into product syngas to flow away from the refractory-lined vessel at a pre-determined molten slag material flow rate;   a gas conduit for directing product syngas to flow from the refractory-lined vessel to a syngas processing apparatus.   
     
     
         7 . The gasification reactor of  claim 6 , wherein the tilting and positioning means is configured such that the vessel can be tilted at a pre-determined tilt angle between 0 to 60 degrees. 
     
     
         8 . The gasification reactor of  claim 6 , the gasification reactor comprising
 a sensor configured within a designated interior wall surface of the said gasifier to receive a flow-stream of hot gasified product syngas evolving from the gasifier,   
       the sensor being configured to perform a multiplicity of measurements over a pre-determined time period to derive a plurality of data signals indicative of said multiplicity of measurements over the pre-determined time period; 
       wherein the sensor further comprises a processor controller, the processor controller being configured to receive the derived plurality of data signals and to perform at least one algorithmic calculation to determine a proximate temperature of said flow-stream of the hot gasified product syngas within the pre-determined time period as sensed by the sensor; and 
       the processor controller being configured to generate a control signal indicative of the proximate temperature addressed to a feedwater flow control valve pump so as to regulate and control the fluid flow of feedwater flowing in a steam generator device in fluid communication with said flow-stream of hot gasified product syngas. 
     
     
         9 . The gasification reactor of  claim 8 , wherein the processor controller is further configured to retrieve from electronic memory a default control signal indicative of a reference feedwater fluid flow rate, addressed to the feedwater flow control valve pump to regulate and control the fluid flow of feedwater flowing in the steam generator device according to said indicative reference feedwater fluid flow rate, in the event where processor controller is unable to generate determined proximate temperature from said received derived plurality of data signals. 
     
     
         10 . The gasification reactor of  claim 8 , wherein the sensor is configured within the designated interior wall surface where the superficial gas velocity of said flow-stream of hot gasified product syngas evolving from the gasifier is at least about 2 meters per second. 
     
     
         11 . The gasification reactor of  claim 8  wherein the sensor is configured to be protruding a proximate distance of at least 1 inch from the surface of the designated wall surface. 
     
     
         12 . The gasification reactor of  claim 8 , the sensor having an extendable member tubular body to travel on a perpendicular axis plane to the designated wall surface axis plane between a proximate distance of 1 inch to 8.5 inches.