This invention relates to the generation of electricity from waste material .

A major and widely-used method of waste disposal is landfill. However, there are significant problems associated with landfill including the lack of available landfill sites, the pollution of groundwater and the uncontrolled generation of gas.

Incineration is an alternative method of waste disposal alleviating the problems of landfill by burning off most of the organic constituents of the waste to leave a solid ash residue for disposal of considerably reduced volume. However, the exhaust fumes resulting from incineration are a source of pollution, and are difficult to treat in order to meet current environmental standards.

The invention is also concerned with the conversion of the waste material into disposable ash.

According to one aspect of the invention, a method of generating electricity from waste material comprises production of gaseous fuel and the driving of electricity generating means by means of combustion of the gaseous fuel, the production of the gaseous fuel comprising heating the waste material without allowing combustion to take place.

According to another aspect of the invention, apparatus for performing the said method comprises an oven, means for feeding the waste material to the oven, means for heating the waste material while in the oven without allowing combustion to take place, means for collecting the gaseous fuel liberated by heating the waste material, electricity producing means, and means for driving the electricity producing means comprising means for combustion of at least some of the collected gaseous fuel.

Means are preferably provided whereby at least some of the collected gaseous fuel is used to heat waste material present in the oven.

The various aspects of the invention will now be described by way of example only, with reference to the accompanying semi-diagrammatic drawings, wherein:-

Figure 1 is a semi-diagrammatic illustration of a first embodiment;

Figure 2 is a diagrammatic illustration of a second embodiment;

Figure 3 is a view in perspective of a fuel block 190, used in a non-illustrated modification,;

Figure 4 is a side view, in section, of the feed means 62 of Figure 2;

Figure 5 is a side view of the gasifier 62 of Figure 2;

Figure 6 is a side view, in section, of the gasifier drum 123 shown in Figure 5;

Figure 7 is an end view in section, taken on the lines VII-VII of Figure 6

Figure 8 is a plan view of feed means suitable for feeding waste material to the gasifier drum of a preferred embodiment,

Figure 9 is an end view, taken on the lines IX-IX of Figure 6,

Figure 10 is a side view, in medial section, of a drum drive wheel 124; and

Figure 11 is an end view, partly in section, which shows how a drum dri e wheel 124 is spring mounted.

With reference to Figure 1, apparatus 1 for producing gaseous fuel from waste material is shown thereby.

The apparatus 1 comprises an oven 2, means 3 for feeding gas-producing waste material to the oven 2, means 4 in the form of gas burners 5 for heating the waste material while in the oven 2, and means 6 for collecting gaseous fuel liberated by heating the waste material.

The oven 2 and feeding means 3 connected thereto are of airtight construction, so that combustion of the waste material is not allowed to take place. The airtight oven 2 has a central gasifier section 15 having an inlet end 15a and an outlet end 15b.

In the gasifier section 15 the waste is subjected to high temperature, say 800°C.

In the embodiment shown in Figure 1, the means 3 for feeding the gas-producing waste material to the oven 2 comprise a garbage hopper 10, a garbage feeder ram 11 and an airtight feeder duct 7. The ram 11 is operated by a hydraulic piston/cylinder unit 12, and serves to compact and to drive the waste along the airtight feeder duct 7 between the hopper 10 and the gasifier section 15 of the oven 2.

The feeder duct 7 is connected to the inlet end 15a and an outlet duct 16 is connected to the outlet end 15b. A screw form of ash rake 17 is sealingly disposed in the outlet duct 16 and is rotatable therein by a motor (not shown) to assist passage of the waste material. The oven 2 has an outlet chimney 18 whereby exhaust gas resulting from use of the gas burners 5 can escape to atmosphere. The chimney 18 is provided with a control damper 19.

The outlet duct 16 extends into a gas/ash collection vessel 25, having an upper end which houses a gas filter 26 and a lower end connected to an ash receptacle 27. Stop valves 28 are provided

whereby ash removed from the oven 2 by the rake 17 is passed to the receptacle 27 without allowing gas to escape from the vessel 25.

In a preferred embodiment (not shown) the ash rake is dispensed with, and vessel 25 is in the form of a cyclone separator for separating the gas and ash.

Gaseous fuel passing through the filter 26 enters a discharge line 29 connected to a gas chiller unit 30. The unit 30 has a hot water/steam outlet 35, a cold water inlet 36, and a covered gas/vapour outlet 37.

The outlet 37 discharges to a separator 38 wherein condensate 39 is collected, and gaseous fuel allowed to- leave by way of a discharge line 40. The condensate comprises water and tars. A float- controlled valve 45 operates to discharge excess condensate to a drain line 46. The gas and tar may, if desired, be recombined in suitable proportions and fed into a cracking chamber to break down larger molecules, including organic toxins, into small molecules, by heating so as to produce a greater overall quantity of gas, and to destroy the organic toxins.

The gas discharge line 40 incorporates a branch line 47 whereby useable gas is led away for employment elsewhere, and a further branch line 48 whereby gas is fed to the oven burners 5 by way of a regulator valve 49 and a gas burner control unit 50.

In addition, or as an alternative merely to start up the gasification process, another supply of gas such as natural gas may be fed to the burner control unit 50 by way of a supply line 51 provided with a control valve 52.

In operation, waste material, such as garbage, is fed to the hopper 10 after being screened, in order to remove unwanted substances such as metals, ceramics and glass.

The waste material is also preferably shredded before being fed to the hopper 10.

In the gasifier section 15, gas is driven off, which enters the line 29 by way of the upper end of collection vessel 25. Meanwhile ash enters the lower end of vessel 25 by way of the valves 28. The upper valve 28 is opened first, and then ash allowed to pass through. The upper valve 28 is then closed, and the lower valve 28 opened to allow the ash to pass into the receptacle 27. The lower valve 28 is then closed.

After cooling, the ash is removed from the receptacle 27 and, for example, spread over a landfill site.

Where the waste material is carbonaceous, (for example, comprising used automobile tyres), if the ash removed is charcoal enriched, then this ash may be used as carbon filter material.

Before the collected gas enters the discharge line 29, it passes through the filter 26 whereby ash particles are removed. The gas then flows through the chiller unit 30 where it is cooled, (to say 5° - 15°C) before passage to the separator 38.

Gas discharged to the line 47 comprises usable gaseous fuel. In general terms, this gas is about 107 _o (by volume) of the gas produced by heating waste material in the oven 2.

A portion of the produced gas is then fed to the oven burners 5, to supplement or replace the gas supplied by the line 51.

Preferably more than one apparatus is made use of. For example two separate apparatus, one of which is fed with relatively low calorific value garbage and the other with relatively high calorific value garbage. The gas produced by each apparatus may then be subsequently mixed, in a controlled manner, to provide usable gas of

desired proportions.

Figure 2 illustrates such an arrangement, wherein relatively low calorific value waste material is supplied to apparatus 60 and relatively high calorific value waste material in a separate (similar) apparatus 68, which operates in parallel with apparatus 60.

In apparatus 60, waste processing takes place at 61. This comprises taking unsorted waste material such as domestic waste material, shredding it, and separating out ferrous and non-ferrous metals, as well as ceramics. Ferrous metals are separated out by magnetic means. Non-ferrous metals are separated out by eddy-current means. An endless belt conveyor subjected to vibration is used to separate out ceramic materials. Similar conveyors are also employed at the metal separation stages.

Separated out metals are employed in subsequent re-cycling operations.

The sorted material comprises small size particles, of about 4.00 to 6.00 mm diameter.

The sorted material may then be subjected to a drying operation, using hot air.

In the embodiment of Figure 2 the material is then fed, using feed means 62, which also serves to compact the material, to an airtight oven or gasifier 63 where it is subjected to high temperature, (say 800°C) without allowing combustion to take place. Here gas is driven off, to be subjected, in a processing unit 64, to processing such as scrubbing, filtration, cooling and storage before being discharged to a mixing container 65. A line 66 (see also Figure 5), connects the gasifier 63 and the processing unit 64. Ash is removed, by way of a valved duct 67, for subsequent use or disposal.

In the case of apparatus 68, unsorted waste material, such as high calorific value industrial material, including packaging and plastics materials are processed at 70 before being fed to a feed means 71. Processing may comprise shredding only. After drying (if required) the waste material is fed to an airtight oven/gasifier 72 by the feed means 71. Gas driven off is subjected to processing at 73. The conveyor means 71, gasifier 72 and processing unit 73 are of substantially identical form to units 62, 63 and 64 respectively.

Ash is removed, by way of a valved duct 74, for subsequent use.

After processing, the gas is discharged to the mixing container 65.

Gas flows from the container 65 along a line 80 to the gas inlet of electricity-producing means comprising a gas turbine generator unit 81 whereby electrical power is produced and fed to a power line 82. The turbine exhaust gases are discharged, by way of a duct 83, to a heat exchanger 84 which incorporates a steam superheater. The heat exchanger 84 has a feed water inlet 85, an outlet 86 for superheated steam and a turbine exhaust gas outlet 87.

Steam discharged from the outlet 86 is fed to further electricity-producing means, comprising a steam turbine generator unit 88 whereby further electrical power is produced and fed to a power line 89. Exhaust from the turbine of the unit 88 is discharged, as hot water, by way of an outlet duct 90.

The gas flow line 80 has a main branch line 91 which feeds subsidiary branch lines 92, 93, whereby gas fuel is fed to the burners (not shown) of gasifiers 63, 72, in order to heat the waste material contained therein. The gasifiers are provided with exhaust gas chimneys 165, 75 corresponding to chimney 18 of Figure 1.

The feed means 62 or 71 of the embodiment in Figure 2 may be used for a single apparatus, for example in place of the feed means 3 of

Figure 1 .

Figure 4 shows one form for the feed means 62 or 71, which comprises a two-stage system using first and second hoppers 100, 101, with first and second screw conveyors 102, 103 disposed in their lower interiors.

Conveyor 102 is driven by an external motor 104, and conveyor 103 by an external motor 105.

The discharge end of conveyor 102 is disposed in a duct 106 interconnecting the lower end of hopper 100 with the upper end of hopper 101, hopper 100 being disposed at a higher level than hopper 101.

A flap valve 107 serving as non-return gas sealing means is disposed at the outlet end of duct 106, and is pivotable about a hinge 109.

The hopper 100 is open to atmosphere. The interior of the hopper 101 is supplied with an inert gas at slight super-atmospheric pressure (about 2.0 lbs per square inch), by way of a line 108 to displace air in the waste. The blanket of inert gas may comprise exhaust gas tapped off chimney 165 (Figure 2) or other unreactive gas such as carbon dioxide or nitrogen. The duct 106 and flap valve 107 serve as gas lock means between the hoppers 100 and 101 and thus restrict entry of air into the hopper 101 by way of the hopper 100.

Processed waste material is supplied to the hopper 100 and is discharged therefrom, in compacted form (so further reducing any air content of the material), by the screw conveyor 102, along the duct 106.

The discharged waste material causes the flap valve 107 to lift and allow the material to enter the hopper 101.

The screw conveyor 103 then discharge-, the transferred waste material, again in compacted form, from the hopper 101 and into the gasifier 63, by way of a feed duct 115.

Figure 8 shows an alternative, preferred, form of the feed means 62 or 71 which comprises a pair of primary hoppers 200, 201 and a secondary hopper 202. The primary hoppers 200, 201 are loaded alternately with waste for feeding to the secondary hopper 202 by respective screw conveyors 206, 208 via respective ducts 207, 209.

When one of the primary hoppers has discharged its load to the secondary hopper, its duct is sealed from the secondary hopper by valve means (not shown) and the hopper is then opened to the atmosphere for ref lling. During ■ refilling, the other primary hopper may be discharging its load to the secondary hopper.

Once a primary hopper is filled it is closed and purged with carbon dioxide or other inert gas, in order to expel air from the waste through a vent valve (not shown) to atmosphere. Following purging the valve means between the hopper and the secondary hopper is opened and a motor 203 or 204 is switched on to drive the respective screw conveyor 206 or 208 to transfer the waste to the secondary hopper 202.

The secondary hopper screw conveyor 210 may be driven continuously by motor 205 to ensure a continuous supply of waste along the duct 211 to the gasifier oven.

The secondary hopper is also supplied with carbon dioxide or other inert gas, maintained at a pressure sufficient to substantially prevent backflow of generated gases to the secondary hopper from the gasifier, or the entry of purged gases from the primary hoppers.

Figure 5 shows the gasifier 63 mounted on a chassis 120. The gasifier 63 comprises a rotatable drum 123 mounted on spring-loaded

drive wheels 124, the peripheries of which engage with circular driving bands 125 carried by the drum 123. The wheels 124 react against the weight of the drum 123 and its contents. The wheels 124 are driven by electric motor and chain drive units (not shown).

The drum 123 has an inlet 126 (Figure 5) and an outlet 127. The inlet 126 is connected to the stationary discharge pipe duct 115 (Figure 4) by way of a rotatable seal unit 128. The outlet 127 incorporates a rotatable gas outlet pipe 129 connected to the stationary line 66 (Figure 2). A gland unit 131 seals the pipe 129 to the line 66 and allows relative rotation therebetween.

The drum 123 is rotatable about a substantially horizontal axis 132. If desired, the drum may be tilted however, by suitable modification of the associated drive and support structure, so that the axis 132 is no longer substantially horizontal.

Figures 6 and 7 show the drum 123 in further detail.

Figure 6 shows the drum 123 provided with means 133 for heating the drum exterior, the means 133 comprising the gas branch line 92 and gas burners 134 supplied thereby.

The drum 123 is of welded steel construction. The interior 140 of the drum houses a mild steel strip 141 wound in spiral form around the rotational axis 132 and secured, by welding, to the inner surface of the drum.

Angular pins 142 are secured to the drum interior adjacent the inlet 126 thereof. The pins 142 vary in effective length and their outer, or unsecured ends are offset relative to the central axis 132. (See Figure 7.) Inwardly projecting strips 143 are secured to the interior of the drum 123. The strips 143 which are equi-spaced, extend longitudinally along the drum interior. They co-operate with the spiral strip 141 and pins 142 in providing structural means

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operable to break or churn up and mix the waste material. The spiral strip 141 further serves as a screw conveyor, causing the broken up material to pass along the interior of the drum 123 towards the outlet 127 thereof. Passage of the material takes about 10 minutes.

In a preferred embodiment the portion of the mild steel strip 141 (Figure 6) that is located in the frusto-conical outlet end of the drum 123 is replaced by channel means for scooping up ash from the bottom of the drum 123 and for raising the ash above the drum axis of rotation 132 so that the ash then slides downwards from the channel means into the drum outlet 127. The channel means may comprise a series of channel defining members 300 attached to the drum which are preferably disposed parallel to planes containing the axis of rotation 132 of the drum 123 as shown in Figure 9, each member being elongate and of a section, such as an L-shaped section suitable to define a respective channel 300a for scooping up and retaining the ash and, on being raised to a position above the axis 132, such as 300b, for allowing the ash to slide down the channel and into the outlet 127.

Alternatively the channel means may comprise a single elongate pipe member (not illustrated) attached to the drum and which typically defines a channel disposed substantially parallel to a plane of the drum containing the drum axis of rotation, one end of the pipe member being provided with an inlet opening, whilst the other end is provided with an outlet opening. Preferably the inlet opening is joined to the end of the spiral channel which is formed in between the coils of the spiral strip 141 in the cylindrical portion of the drum 123 and which is that end of the spiral channel nearest to the outlet 127, such that substantially all of the ash leaving that end of the spiral channel enters directly into the inlet opening of the pipe as this is raised during rotation of the drum 123. When the pipe member has been lifted up to a sufficient level, the ash slides down through the pipe member and out of the outlet opening into outlet 127. The end of the pipe member having the outlet opening preferably projects into the outlet 127, which may conveniently be

provided with ash driving means, such as a further spiral strip of mild steel, for driving the ash along outlet 127 away from the drum 123. Guide means adjacent to the outlet opening of the pipe member may be desirable, for example in the form of a plate, for directing the ash from the outlet opening into the ash driving means.

As shown in Figure 5, the rotatable drum 123 is housed in a box-like enclosure 150 lined with thermal insulation 151.

Figure 10 shows a drive wheel 124 in further detail. The wheel is of composite form and comprises a steel central hub portion 155, with a keyway 156, for mounting on a shaft 157 (Figure 9), a steel outer rim or tyre portion 158, and an intermediate portion 159 of load accepting heat insulating material. Bolts 165, 166, secure the three portions 155, 158, 159 together.

Figure 11 shows how the drive wheels 124 are spring-mounted. The shaft 157 of a wheel 124 is mounted for rotation between the forks of a bifurcated support bracket 170. The bracket 170 is mounted on the upper end of a pin 171 slidably located within a support block 172 secured to the chassis 120. A compression spring 173 is disposed between the lower end of the pin 171 and a disc 174 disposed within the interior 175 of the support block 172. A lockable adjusting screw 176 mounted for rotation in the lower end of the block 172 is used to adjust the compressive load on the spring 173, and thereby the spring loading on the drive wheel 124.

In a non-illustrated modification, the waste material is compacted under substantial pressure so as to form cylindrical fuel blocks 190 ⁽ Figure 3) before being fed to the gasifier 63. A fuel block 190 is about 90.00 mm in diameter, about 300.00 mm in length, and weighs about 250.00 g .

The discrete fuel blocks 190 are subsequently fed, under pressure imposed by a feeding ram, into the drum 123 of the gasifier 63.