CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority from U.S. Provisional Patent Application No. 61/801, 147, filed on March 15, 2013, which is incorporated by reference herein in its entirety.

BACKGROUND

[0002] The extraction of bio oil from biomass for use as a biofuel is an area of interest in the search for reliable alternative energy sources. Biomass may be subjected to pyrolysis to create a hot pyrolysis vapor. Bio oil may be extracted from the hot pyrolysis vapor. Additionally, biomass may be subjected to gasification to create a syn gas.

[0003] Systems and apparatuses are needed for the pyrolysis and gasification of biomass.

SUMMARY

[0004] In one embodiment, a single pyrolysis gasification loop for pyrolyzing a biomass material is provided, the single pyrolysis gasification loop comprising: a reactor auger operatively connected to at least one of a biomass inlet and a vapor outlet; and a return auger; wherein the reactor auger and the return auger are operatively connected by at least one of a reactor outlet and a return outlet; wherein the reactor auger is operable to advance the biomass material to the return auger via the reactor outlet; wherein the return auger is operable to advance the biomass material to the reactor auger via the return outlet; and wherein the reactor auger is operable to pyrolyze the biomass material.

[0005] In another embodiment, a single pyrolysis gasification loop for gasifying a char material is provided, the single pyrolysis gasification loop comprising: a reactor auger operatively connected to at least one of a heat inlet and a gas outlet; and a return auger; wherein the reactor auger and the return auger are operatively connected by at least one of a reactor outlet and a return outlet; wherein the reactor auger is operable to advance the char material to the return auger via the reactor outlet; wherein the return auger is operable to advance the char material to the reactor auger via the return outlet; and wherein the reactor auger is operable to gasify the char material.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The accompanying figures, which are incorporated in and constitute a part of the specification, illustrate example systems and apparatuses, and are used merely to illustrate example embodiments.

[0007] FIG. 1 illustrates an example arrangement of a single pyrolysis gasification loop ("PGL") operating in a pyrolysis mode.

[0008] FIG. 2 illustrates an example arrangement of a single PGL operating in a gasification mode.

DETAILED DESCRIPTION

[0009] The processing of biomass to extract bio oil therefrom may involve the pyrolysis of biomass to create a hot pyrolysis vapor. Pyrolysis processes may include fast pyrolysis of biomass material at temperatures of about 500 °C. When biomass undergoes pyrolysis, three groups of components may be created, including: non-condensable gases, vapor that may be quenched into bio oil, and solids known as char and coke.

[0010] Char and coke may be gasified utilizing a gasification process to generate a produce, such as a syn gas product, and energy in the form of heat.

[0011] FIG. 1 illustrates an example arrangement of a PGL 100 operating in a pyrolysis mode. PGL 100 may comprise a series of augers, including a reactor auger 102 and a return auger 104. PGL 100 may be configured to intake biomass material via a biomass inlet 106. PGL 100 may be configured to outlet a pyrolysis vapor via a vapor outlet 108. Biomass inlet 106 may be operatively connected to at least one of reactor auger 102 and return auger 104. Vapor outlet 108 may be operatively connected to at least one of reactor auger 102 and return auger 104.

[0012] PGL 100 may comprise a 1-3 ton waste to energy conversion ("WEC") system comprising two separate modules. A first module may be configured for feed pretreatment (such as sizing) and/or thermochemical conversion, while a second module may be configured for production of fuels and/or electric power. Each of the first module and the second module may be configured to fit in containers having dimensions of about 8 ft. by about 8 ft. by about 20 ft. PGL 100 may be configured to fit entirely in a container having dimensions of about 8 ft. by about 8 ft. by about 20 ft. PGL 100 may be configured to fit entirely in a container having dimensions less than about 8 ft. by about 8 ft. by about 20 ft. PGL 100 may be operatively connected to upstream and downstream components, such as dryers, size attrition devices, and electrical generator sets.

[0013] In one embodiment, PGL 100 is configured to be very compact. PGL 100 may not require fluidization gas. PGL 100 may not require the associated auxiliary equipment required for conventional thermochemical conversion technologies. PGL 100 may not require a separate continuous heating system. PGL 100 may include minimal parasitic loss. PGL 100 may include thermal storage and temperature control via phase change media. PGL 100 may exceed 50% net energy recovery. PGL 100 may be configured to simultaneously produce both a low oxygen bio oil and a syn gas.

[0014] The low oxygen bio oil generated by PGL 100 may be a stable product. The low oxygen bio oil may be stored for later use. The low oxygen bio oil may be used in a modified diesel engine. The low oxygen bio oil may be converted to a hydrocarbon fuel that can be used by a vehicle.

[0015] The syn gas generated by PGL 100 may be used to produce electricity during operation of PGL 100. The syn gas may be utilized in an electrical generation system.

[0016] The biomass material may comprise any of a variety of lignocellolosic feed materials. The biomass material may comprise a wood or plant material. The biomass material may comprise waste.

[0017] PGL 100 may operate in parallel with additional PGL systems. A plurality of PGL systems, including PGL 100 may be oriented inside an insulated container. A plurality of PGL systems, including PGL 100, may be oriented with a phase change material in an insulated container. A plurality of PGL systems, including PGL 100 may be substantially surrounded by a phase change material in an insulated container. A plurality of PGL systems, including PGL 100 may be oriented with a phase change material in an insulated container, wherein at least one of reactor auger 102 and return auger 104 may be substantially surrounded by a phase change material.

[0018] Biomass may be introduced to PGL 100 via biomass inlet 106. Biomass may first be introduced into reactor auger 102. Reactor auger 102 may comprise an auger device within a substantially cylindrical housing. The auger device may be configured to advance material longitudinally along the interior of the substantially cylindrical housing. Biomass may be pyrolyzed within the cylindrical housing of reactor auger 102. Biomass may be exposed to temperatures of about 500 °C within reactor auger 102. Reactor auger 102 may contain granular heating media. Biomass may be contacted with granular heating media within reactor auger 102. Biomass may be pyrolyzed by contact with granular heating media within reactor auger 102. [0019] Biomass within reactor auger 102 may undergo flash pyrolysis creating at least one of a vapor and a char (e.g., a fixed carbon). The vapor may exit PGL 100 via vapor outlet 108. The char may exit reactor auger 102 via a reactor outlet 110. Reactor outlet 110 may be operatively connected to return auger 104. Reactor outlet 110 may be configured to transfer char from reactor auger 102 to return auger 104. Char may be transferred from reactor auger 102 to return auger 104 along with granular heating media. Char may be mixed with granular heating media and transferred from reactor auger 102 to return auger 104.

[0020] Return auger 104 may comprise an auger device within a substantially cylindrical housing. The auger device may be configured to advance material longitudinally along the interior of the substantially cylindrical housing. Material advancing through return auger 104 may be returned to reactor auger 102 via a return outlet 112. Return outlet 112 may be operatively connected to reactor auger 102. Return outlet 112 may be configured to transfer material, including char or granular heating media, from return auger 104 to reactor auger 102.

[0021] In one embodiment, PGL 100 comprises reactor auger 102 and return auger 104 oriented in a continuous loop. The continuous loop may be formed by at least reactor auger 102, reactor outlet 110, return auger 104, and return outlet 112. Reactor auger 102 and return auger 104 may comprise heating media, including granular heating media.

[0022] In one embodiment, reactor auger 102 is operatively connected to a reactor motor 114. Reactor motor 114 may comprise any motor capable of causing the auger device within reactor auger 102 to rotate. Reactor motor 114 may be configured to cause the auger device within reactor auger 102 to rotate at any of a variety of rotational velocities. Reactor motor 114 may be a stepper motor configured to cause the auger device within reactor auger 102 to rotate in a number of equal steps. [0023] In one embodiment, return auger 104 is operatively connected to a return motor 116. Return motor 116 may comprise any motor capable of causing the auger device within return auger 104 to rotate. Return motor 116 may be configured to cause the auger device within return auger 104 to rotate at any of a variety of rotational velocities. Return motor 116 may be a stepper motor configured to cause the auger device within return auger 104 to rotate in a number of equal steps.

[0024] PGL 100 may operate for a fixed time period of operation in pyrolysis mode, after which PGL operation may be switched to gasification mode (illustrated in FIG. 2). PGL 100 may operate for any of a variety of desired time periods, including a period of time on the order of minutes. A user may establish and adjust the time period of operation of the PGL system in pyrolysis mode or gasification mode.

[0025] FIG. 2 illustrates an example arrangement of a PGL 200 operating in a gasification mode. PGL 200 may comprise a series of augers, including reactor auger 102 and return auger 104. Reactor auger 102 may be operatively connected to reactor motor 114, while return auger 104 may be operatively connected to return motor 116. Reactor auger 102 and return auger 104 may be operatively connected by reactor outlet 110 and return outlet 112.

[0026] PGL 200 may be configured to intake steam or heated air via a heat inlet 206. PGL 200 may be configured to outlet a gas, such as syn gas, via a gas outlet 208. In one embodiment, PGL 200 gasifies a char or coke in reactor auger 102. Reactor auger 102 may comprise a temperature greater than about 500 °C. In another embodiment, reactor auger 102 comprises a temperature greater than about 660 °C. Gasification of a char or coke in reactor auger 102 may yield a syn gas, which may exit PGL 200 via gas outlet 208. Heat inlet 206 may be operatively connected to at least one of reactor auger 102 and return auger 104. Gas outlet 208 may be operatively connected to at least one of reactor auger 102 and return auger 104.

[0027] In one embodiment, PGL 200 comprises the same system and components as PGL 100. In another embodiment, PGL 200 comprises a wholly separate system from PGL 100. PGL 200 may comprise the same system and components as PGL 100, with the exception of the addition of heat inlet 206 and gas outlet 208.

[0028] In one embodiment, PGL 200 comprises the same system and components as PGL 100, wherein biomass entering PGL 100 via biomass inlet 106 is replaced with hot air or steam entering PGL 200 via heat inlet 206. Biomass inlet 106 and heat inlet 206 may be the same inlet tasked for different purposes when the PGL is operating in different modes. PGL 200 may comprise the same system and components as PGL 100, wherein vapor exiting PGL 100 via vapor outlet 108 is replaced with syn gas exiting PGL 200 via gas outlet 208. Vapor outlet 108 and gas outlet 208 may be the same outlet tasked for different purposes when the PGL is operating in different modes.

[0029] PGL 200 may be configured to gasify char and coke. The char or coke may be left over from pyrolysis performed in PGL 100. PGL 200 may be configured to gasify and partially combust char or coke. PGL 200 may be configured to generate a gas, such as syn gas, from the gasification of char. PGL 200 may gasify at least a portion of the char or coke and leave noncombustible ash. The noncombustible ash may exit PGL 200 via gas outlet 208 with a gas.

[0030] PGL 200 may be configured to generate energy in the form of heat from the gasification of char. The energy generated by PGL 200 may be sufficient to provide at least a portion of the process heat and at least partially maintain the necessary reaction temperature in PGL 100 during pyrolysis, and/or in PGL 200 during gasification. [0031] In one embodiment, a plurality of PGL systems are configured to operate simultaneously, with some operating in pyrolysis mode (e.g., PGL 100) and others operating in gasification mode (e.g., PGL 200). A plurality of PGL systems may be oriented within a container and thermally coupled via phase change media. A plurality of PGL systems may be operatively connected and share headers for biomass feed, heated air, syn gas, and pyrolysis vapor. The headers may comprise dampers configured to control the flow of biomass feed, heated air, syn gas, and pyrolysis vapor. The dampers may be controlled by at least one computer.

[0032] In one embodiment, switching between pyrolysis mode (e.g., PGL 100) and gasification mode (e.g., PGL 200) includes the use of dampers. The operation of PGL 100 and gasification 200 may include the use of dampers. The dampers may be controlled by a computer. The dampers may be configured to manage desired reactor temperature.

[0033] Phase change media may be selected, and thermal coupling between the PGL systems (e.g., PGL 100 or PGL 200) may be designed, such that the absorption and release of the latent heat of fusion is at an appropriate temperature. Phase change media may be selected, and thermal coupling between the PGL systems (e.g., PGL 100 and PGL 200) may be designed, such that sufficient temperature gradients are allowed in the solid and liquid phase of phase change media so that the PGL systems operate at the required temperatures in the pyrolysis mode (e.g., PGL 100) and the gasification mode (e.g., PGL 200). If more energy than necessary is generated by PGL 200 (gasification mode), phase change media may melt and an excessive temperature increase within PGL 200 may be prevented. If less energy than is sufficient is generated in PGL 100 (pyrolysis mode), phase change media may solidify, providing the necessary heat for PGL 100. Phase change media may comprise a metal, such as aluminum. Phase change media may comprise a binary metal, such as Al-Cu. Phase change media may comprise binary salts, such as nitrate salts (e.g., a 03-K Os) with a temperature range between about 220 °C and about 540 °C. A control system (not shown) may monitor temperatures of the PGL systems to determine the mode of operation of individual PGL systems. A control system (not shown) may monitor any of various process parameters of the PGL systems to determine the mode of operation of individual PGL systems.

[0034] Granular heating media may comprise an inert substance. Granular heating media may comprise sand. Granular heating media may comprise an acidic catalyst. Granular heating media may comprise zeolites (e.g., HZSM-5, H-Beta, H-Mordenite, or the like). Granular heating media may comprise metal oxides (e.g., Zr0 ₂ , Ti0 ₂ , CaO, ZnO, Dolomite, or the like). Granular heating media may comprise FCC catalysts, including spent FCC catalysts. Catalysts may be used during pyrolysis for effectively converting carboxylic acids to ketones, deoxygenating reactive compounds such as aldehydes and ketones, or depolymerizing heavy components. Catalysts may also be used during pyrolysis for effective depolymerization of pyrolysis vapor with relatively modest increase in reaction temperature.

[0035] Selection of the catalyst used as heating media, as well as selection of the reaction temperature, may enable selective operation of PGL 100 or PGL 200 for either pyrolysis or low temperature gasification of the biomass feed. Low temperature gasification may reduce heat loss from PGL 100 or PGL 200 and increase the thermal efficiency of the pyrolysis or gasification processes.

[0036] To the extent that the term "includes" or "including" is used in the specification or the claims, it is intended to be inclusive in a manner similar to the term "comprising" as that term is interpreted when employed as a transitional word in a claim. Furthermore, to the extent that the term "or" is employed (e.g., A or B) it is intended to mean "A or B or both." When the applicants intend to indicate "only A or B but not both" then the term "only A or B but not both" will be employed. Thus, use of the term "or" herein is the inclusive, and not the exclusive use. See Bryan A. Garner, A Dictionary of Modern Legal Usage 624 (2d. Ed. 1995). Also, to the extent that the terms "in" or "into" are used in the specification or the claims, it is intended to additionally mean "on" or "onto." To the extent that the term "selectively" is used in the specification or the claims, it is intended to refer to a condition of a component wherein a user of the apparatus may activate or deactivate the feature or function of the component as is necessary or desired in use of the apparatus. To the extent that the term "operatively connected" is used in the specification or the claims, it is intended to mean that the identified components are connected in a way to perform a designated function. To the extent that the term "substantially" is used in the specification or the claims, it is intended to mean that the identified components have the relation or qualities indicated with degree of error as would be acceptable in the subject industry. As used in the specification and the claims, the singular forms "a," "an," and "the" include the plural. Finally, where the term "about" is used in conjunction with a number, it is intended to include ± 10% of the number. In other words, "about 10" may mean from 9 to 11.

[0037] As stated above, while the present application has been illustrated by the description of embodiments thereof, and while the embodiments have been described in considerable detail, it is not the intention of the applicants to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art, having the benefit of the present application. Therefore, the application, in its broader aspects, is not limited to the specific details, illustrative examples shown, or any apparatus referred to. Departures may be made from such details, examples, and apparatuses without departing from the spirit or scope of the general inventive concept.