RECYCLING OF INDUSTRIAL AND ORGANIC WASTES THAT CONTAIN ENERGY BY INNOVATIVE GASIFICATION METHOD

Technical Field:

The invention relates to a method for mixing well the material to be gasified in reactors (4-5), producing high-quality (17) gas and benefiting also from highly humid products of materials to be gasified by means of a special fire brick (21) that is resistant to high temperature and that will be coated around the gasification reactors (4,5) like bearings inside the gasification unit (3) in order to enable a rigid heat distribution, i.e. the same temperature value at every point of reactors; a homogenous distribution, in the pre- reactor (4) and the main reactor (5) that are located in the gasification unit (3) for industrial and organic wastes that contain any kind of energy especially in energy and recycling industry.

Background of the Invention:

Various gasification methods have been developed in the last 20 years. As a result of gained experience, different gasification (pyrolysis) technology applications were developed.

In existing technologies, material to be gasified is provided to the gasification unit from above by means of the fluidized-bed method. Thermal energy required for the process is provided by combustion of material in the lower part of the reactor. For this process to be efficient, material to be gasified should be dried at least 90% leading to energy loss and reduced gas quality.

Material to be gasified by thermal energy is in ignition state. In this method, methane gas to be produced is combusted by direct combustion method. Temperature value should be the same at each point of the reactor in order to have an efficient pyrolysis process. There are practical challenges in reaching a homogenous temperature distribution with this method. Moreover, flue gases from the combustion unit also merge with the pyrolysis gas due to direct combustion. This results in reduced gas quality. Furthermore, due to direct combustion, methane gas produced in the process is burnt. This results in an inefficient co-generation in converting the pyrolysis gas into electric power.

Gasification of wastes with a low content of organic material is very hard and low in efficiency using existing pyrolysis methods.

In existing pyrolysis methods, materials to be gasified should be at a certain size. Otherwise, problems occur while moving the material to be gasified in the fluidized bed. It causes blockage.

Produced gas is either used directly after passing from gas cleaning units or converted to electric power by being burnt in co-generation.

Description of the Figures:

Present invention will be described in more detail by way of only illustration and by means of referring to the figures attached.

Figure 1 is a process view of the system.

Figures to help understand the present invention are numbered as in the attached picture and they are given below with their names.

Part References:

1 - Fuel Tank

2 - Combustion Unit,

3 - Pyrolysis Unit,

4 - Pre-gasification Spiral Reactor,

5 - Final gasification Main Spiral Reactor,

6 - Cyclone tank,

7 - Particle cyclone,

8 - Gas cleaning filter,

9 - Co-generation area

10 - Tank for the material to be gasified

11 - Flue Gas Exchanger, 12 - Flue Gas

13 - Transport Conveyor for degassed material

14 - Gas cooling unit,

15 - Preheating section for the material to be gasified

16 - Degassed material (Coke)

17 - Pyrolysis gas,

18 - Flue gas from co-generation,

19 - Electric Power produced by co-generation,

20 - Waste heat produced by co-generation,

21 - Fire brick

Object of the Invention:

Present invention aims to eliminate the abovementioned problems. Present invention is a Pyrolysis (gasification) method for industrial and organic wastes containing any kind of energy with maximum efficiency.

Pyrolysis unit (3) consists of two gas proof spiral transport reactors (4-5). Tank for the material (industrial and organic wastes that contain energy) to be gasified (10) is passed through two gas proof and horizontally aligned spiral transport reactors (4-5) in the pyrolysis process unit (3) so that the flow and gasification are performed safely. Pre- gasification is performed in the upper spiral (4) and the final gasification in the lower spiral (5).

In order to produce gas efficiently in the pyrolysis process, heat distribution in the pre- reactor (4) and the main reactor (5) should be rigid; in other words temperature value should be the same at every point of the reactors. This is accomplished by means of a special firebrick (21) that will be coated around the gasification reactors (4,5) like bearings inside the pyrolysis unit and that is resistant to high temperature. Thus, pre- gasification is performed in the pre-reactor and final gasification in the main reactor. The material to be gasified in the pyrolysis process yields synthesis gas, coke and mineral matter. In contrast to existing pyrolysis methods, in which thermal energy is directly provided; this method provides thermal energy indirectly by means of coating the firebrick (21) around the pre-reactor (4) and main reactor (5) like a jacket. Therefore, providing the required thermal energy for pyrolysis this way enables a homogenous temperature distribution in reactors; the temperature value is the same at every point of reactors; spot overheating, cooling of reactors and material expansion, stress due to overheating and cooling is minimized. This prevents material fatigue and prolongs the life of the plant significantly. Since reactors (4-5) are mounted in a way that the inner jacket of the firebrick (21) is not fixed, material stress that may occur in the pyrolysis unit (3) due to expansion is eliminated. Moreover, due to energy storage in the firebrick; transient fluctuations in the combustion unit (2) that provides the thermal energy for pyrolysis process are balanced and no adverse effects occur in gasification.

Mixing of the material to be gasified is perfectly performed due to the spirals in the reactors (4-5). Therefore, temperature distribution is homogenous in the reactors.

Residual coke (16) after gasification is burnt in the combustion unit (2) by means of the spiral transport conveyor (13) and provides the required thermal energy for pyrolysis. If the calorific value of this coke (16) is low, required thermal energy for the process is provided by adding some other fuels to the combustion unit (2). Natural gas, wood chips and coal fossil fuels may be used for this purpose.

Produced pyrolysis gas (17) is first cleaned by various filters (8) and it can be used in desired fields such as fuel in cars, provided to the gas network or burnt in co-generation (19) to produce electric power.

In existing pyrolysis methods, material to be gasified should have a maximum humidity rate of 10% since thermal energy is provided directly. Otherwise, gasification cannot be performed completely. Whereas, in this method material to be gasified may have a humidity rate up to 40% since thermal energy is provided indirectly. Having a high humidity rate is not a disadvantage, on the contrary it increases the process efficiency 70%. Moreover, since the material to be gasified does not require high dryness, drying energy consumption is significantly reduced.

Detailed Description of the Invention:

In this detailed description, recycling of industrial and organic wastes that contain energy by innovative gasification method of the invention is described by way of illustration in a manner not to pose any limiting effects, for the better understanding of the invention.

The invention consists of a fuel tank (1), combustion unit (2), pyrolysis unit (3), pre- gasification spiral reactor (4), final gasification main spiral reactor (5), cyclone tank (6), particle cyclone (7), gas cleaning filter (8), co-generation area (9), tank for the material to be gasified (10), flue gas exchanger (11), flue gas (12), transport conveyor for degassed material (13), gas cooling unit (14), preheating section for the material to be gasified (15), degassed material (16), pyrolysis gas (17), flue gas from co-generation (18), electric power produced by co-generation (19), waste heat produced by co- generation (20) and firebrick (21). In the system for recycling of industrial and organic wastes that contain energy by means of the innovative gasification method of the invention, organic wastes to be gasified are conveyed to the tank for the material to be gasified (10). Organic material to be gasified is first gasified in the pre-gasification spiral reactor (4) and then in the final gasification main spiral reactor (5). In the system, required thermal energy for gasification is obtained by burning the fuel in the fuel tank (1) in the combustion unit (2). In the pyrolysis unit, firebrick (21) is coated on every surface of the pre-gasification spiral reactor (4) and final gasification main spiral reactor (5) like a jacket. Gasified organic material gas and wastes thereof are provided to the cyclone tank (6). Here, organic material wastes are decomposed in the degassed material tank (coke) (16). Yielded pyrolysis gas (17) arrives at the particle cyclone (7). Particles retained by the particle cyclone (7) and coke in the degassed material tank (16) are transported to the combustion unit (2) by means of the transport conveyor for degassed material (13). Pyrolysis gas (17) arrives at the co-generation tank (9) for electric cycle after cooling in the gas cooling unit (14) and passing through the gas cleaning filter (8). In the co-generation tank (9), pyrolysis gas (3) is burnt and converted to the electric power produced by co-generation (19). In the co-generation tank (9), flue gas from co-generation (18) and waste heat produced by co-generation (20) are eliminated by outlets. In the system, tank for the material to be gasified (10), flue gas exchanger (11) connected to the pyrolysis unit (3) and flue gas (12) are heated in the pre-heating tank for the material to be gasified (15) in order to save energy.

It is possible to develop various embodiments of the mechanism of the invention within the frame of this basic concept, wherein the invention is essentially as given in claims and it cannot be limited by the examples herein.